Disassembly

Transfer Case














Special Tool(s)

Disassembly








Disassembled View
1. Remove the transfer case.
2. Remove the dampener.





3. Remove the heat shield.





4. WARNING: Make sure the Holding Fixture lock pin is secure.

Using the special tool, secure the transfer case to the bench.





5. Index-mark the rear output flange and the rear output shaft.





6. Using the special tool to hold the rear output flange, remove the nut.





7. Remove the rear output flange and the output shaft yoke washer.





8. Remove the oil seal.





9. Using the special tools, remove the oil seal.





10. Remove the coil wire pin from the electrical connector.
1 Remove the connector interlock.
2 Remove the coil wire pin.
1 Use electrical connector pin extractor tool.








11. Remove the front and rear output shaft speed sensor bolts. Carefully remove the sensors from the transfer case.





12. Remove the four bolts and the transfer case shift motor.

13. NOTE: Inspect the tone wheel teeth for damage.

If necessary, remove and discard the tone wheel.





14. Remove the 17 bolts.





15. Remove the clutch coil assembly nuts.





16. Separate the transfer case halves at the transfer case pry bosses.








17. Using the special tools, remove the front output shaft rear bearing and the rear output shaft support bearing.





18. Remove the thrust bearing.





19. Remove the cam and coil housing assembly.





20. Remove the apply cam and balls.
1 Remove the steel balls.
2 Remove the apply cam.





21. Remove the wave spring.





22. Remove the snap ring.





23. CAUTION: When removing or installing the clutch pack assembly, do not separate the clutch pack assembly. Keep tension on the clutch pack upon removal. Set the clutch pack assembly on the bench in the same position as it was located in the transfer case. The thrust washer in the lower clutch pack uses tabs to hold it in place. If the thrust washer is not in place, a transfer case clearance problem can occur.

Remove the clutch pack assembly.





24. Remove the tone wheel.





25. Remove the drive chain and the sprockets as an assembly.





26. Remove and clean the oil pan magnet.





27. Remove the thrust washer.





28. CAUTION: Do not disassemble the pump assembly.

Remove the pump assembly and the rear output shaft as an assembly.





29. CAUTION: Do not disassemble the electric shift cam assembly.

Remove the electric shift cam assembly.





30. Remove the reduction shift fork and the high-low collar as an assembly.





31. Remove the shift rail.





32. Using the special tool, remove the oil seal.





33. Remove the front planetary gear set assembly.
1 Expand the snap ring.
2 Remove the front planetary gear set assembly.





34. Remove the ring gear, if necessary.
1 Remove the snap ring.
2 Remove the ring gear.





35. Using a drift and hammer, remove the output shaft bushing and bearing, if necessary.





36. If planetary gear carrier support bearing removal is necessary, remove the snap ring.





37. Using a suitable press and the special tool, remove the planetary gear carrier support bearing.





38. Remove the dampener snubber.








39. Holding the front output shaft and flange, remove the snap ring and the front output shaft and flange.





40. Using the special tools, remove the oil seal.





41. Using the special tools, remove the front output shaft support bearing.





42. Remove the shifter shaft seal.