Disassembly and Assembly

Transfer Case-AWD











Special Tool(s)

CAUTION: Discard all seals after removing them.





1. WARNING: Make sure the special tool lock pin is secure.

Using the special tool, secure the transfer case to a bench.
2. Remove the dampener.





3. If not done previously, remove the drain plug and drain the fluid.





4. Index-mark the rear output shaft flange and the upper output shaft.











5. Remove the components in the order indicated in the illustration and table.
6. To assemble, reverse the disassembly procedure.

Item 1: Output Flange Nut Disassembly Note





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

Item 6: Case Disassembly Note





1. Using a pry bar, separate the rear case from the front case.
^ Pry only at the transfer case pry bosses.

Item 7: Upper Output Shaft and Ring Gear Disassembly Note





1. Remove the upper output shaft and the ring gear.
^ Expand the snap ring.

Item 15: Bearing Disassembly Note





1. Using the special tools, remove the bearing.

Item 21: Upper Drive Sprocket Disassembly Note





1. Remove the upper drive sprocket, overdrive sun gear, drive chain and the lower drive sprocket as one assembly.

Item 27: Bearing Disassembly Note





1. Using the special tools, remove the bearing.

Item 28: Snap Ring Disassembly Note





1. Hold the front output shaft while removing the snap ring.

Item 31: Bearing Disassembly Note





1. Using the special tools, remove the bearing.

Item 1: Output Flange Nut Assembly Note





1. While holding the flange with the special tool, tighten the nut.

Item 6: Case Assembly Note





1. CAUTION: Applying excess silicone gasket and sealant can damage the internal components.

Apply a 3 mm (0.125 inch) bead of silicone gasket and sealant on the rear case mating surface.

Item 7: Upper Output Shaft and Ring Gear Assembly Note





1. Install the upper output shaft and ring gear in the rear case half.
^ Expand the snap ring. Install the upper output shaft and ring gear assembly.
^ Release the snap ring.

Item 10: Yoke to Flange Seal Assembly Note





1. Using the special tool, install the seal.

Item 24: Lower Drive Sprocket Assembly Note





1. Assemble the overdrive sun gear, the upper drive sprocket. lower drive sprocket and the drive chain.
^ Align the blind spline on the lower drive sprocket with the narrow spline on the overdrive sun gear.





2. Install the overdrive sun gear, the upper sprocket, the lower sprocket and the drive chain as an assembly.

Item 27: Bearing Assembly Note





1. Using the special tool, install the bearing.

Item 31: Bearing Assembly Note





1. Using the special tools, install the bearing.

Item 32: Seal Assembly Note





1. Using the special tool, install the seal.