Disassembly
Transfer Case
Special Tool(s)
Disassembly
1. CAUTION: Discard all seals after removing them.
Remove the transfer case from the vehicle.
2. WARNING: Make sure the Holding Fixture lock pin is secure.
Using the special tool, secure the transfer case to a bench.
3. Remove the dampener.
4. If not done previously, remove the drain plug and drain the fluid.
^ Install the drain plug when finished draining.
5. Index-mark the rear output flange and the upper output shaft.
6. Using the special tool to hold the output flange, remove the nut.
7. Remove the output flange and the output shaft yoke washer.
8. Remove the oil seal.
9. Remove the 17 bolts.
10. Using a pry bar, separate the rear case from the front case.
^ Pry only at the transfer case pry bosses.
11. CAUTION: Do not remove the needle bearing from the upper output shaft.
Remove the upper output shaft and the ring gear. 0
^ Expand the snap ring.
12. Remove the bearing.
13. Remove the seal.
14. Remove the snap ring, then separate the upper output shaft from the ring gear.
15. Remove the oil scoop.
^ Using a screwdriver, carefully pry the oil scoop out.
16. Remove the snap ring retaining the bearing on the upper output shaft.
17. Using the special tools, remove the bearing.
18. Remove the damper snubber.
19. Remove the output shaft thrust washer.
20. Remove the front planetary gear assembly.
21. Remove the thrust washer.
22. Remove the overdrive sun gear, the upper drive sprocket, the drive chain, and the lower drive sprocket.
23. Remove the viscous coupling.
24. Remove the input shaft.
25. Using the special tools, remove the bearing.
26. Holding the front output shaft, remove the snap ring and the front output shaft.
27. Using the special tools, remove the bearing, then remove the seal.