Transfer Case - 1-Speed Torque-On-Demand
Transfer Case - 1-Speed Torque-On-DemandSpecial Tool(s) (Part 1):
Special Tool(s) (Part 2):
Special Tool(s) (Part 3):
Material:
Disassembly
1. CAUTION: Discard all seals after removing them.
Remove the transfer case.
2. WARNING: Make sure the holding fixture lockpin is secure.
Using the special tool, secure the transfer case to the bench.
3. If not previously done, remove the drain plug and drain the fluid.
^ When finished draining, install the drain plug and tighten to 20 Nm (15 ft. lbs.)
4. Using the special tool to hold the output flange, remove the nut.
5. Remove the output shaft yoke washer.
6. Using the special tool, remove the output flange.
7. Remove and discard the output flange oil seal.
8. Using the special tools, remove and discard the yoke-to-flange seal.
9. Remove the coil wire pin from the electrical connector.
^ Remove the connector interlock.
^ Remove the coil wire pin (pin 16).
^ Use the electrical connector pin extractor tool.
10. Remove the 17 transfer case bolts.
11. Remove the 3 clutch coil assembly nuts.
12. Separate the transfer case halves at the transfer case pry bosses.
13. Remove the snap ring, then using the special tool, remove the rear output shaft support bearing.
14. Using the special tool, remove the front output shaft rear bearing.
15. Remove the thrust bearing.
16. Remove the cam and coil housing assembly.
17. Remove the apply cam and 3 steel balls.
18. Remove the wave spring.
19. Remove the snap ring.
20. 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.
21. Remove the drive chain and the 2 sprockets as an assembly.
22. Remove and clean the oil pan magnet.
23. Remove the thrust washer.
24. CAUTION: Do not disassemble the pump assembly.
Remove the pump assembly and the rear output shaft as an assembly.
25. Using the special tool, remove the oil seal.
26. While holding the front output shaft and flange, remove the snap ring.
27. Remove the front output shaft and flange.
28. Using the special tools, remove the oil seal.
29. Using the special tools, remove the front output shaft support bearing.
Assembly
1. Using the special tools, press the front output shaft support bearing into the case.
2. Using the special tool, install the oil seal.
3. Using the special tool, install the oil seal.
4. Install the front output shaft and flange and snap ring.
5. CAUTION: Do not disassemble the pump assembly.
Install the pump assembly and the rear output shaft as an assembly.
6. Install the thrust washer.
7. Install the oil pan magnet.
8. Install the drive chain and the 2 sprockets as an assembly.
9. 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.
Install the clutch pack assembly.
10. CAUTION: Use a new snap ring.
Install the snap ring.
11. Install the wave spring.
12. Install the apply cam and 3 steel balls.
13. Install the cam and coil housing assembly.
14. Install the thrust bearing.
15. Using the special tools and a suitable press, install the front output shaft rear bearing into the case.
16. Using the special tools and a suitable press, install the rear output shaft rear bearing into the case.
17. Position and support the clutch coil assembly, then install the 3 nuts.
^ Tighten to 10 Nm (89 inch lbs.)
18. CAUTION: Applying excess silicone rubber can damage the internal components.
Apply a 3 mm (0.11 inch) bead of silicone rubber on the rear case mating surface.
19. Assemble the front and rear case halves.
20. Install the transfer case bolts.
^ Tighten to 25 Nm (18 ft. lbs.) evenly in a star pattern.
21. Install the yoke-to-flange oil seal.
22. Install a new output flange oil seal.
23. NOTE: Align the index marks made during disassembly.
Install the output flange.
24. Install the output shaft yoke washer.
25. Using the special tool to hold the output flange, install the nut.
^ Tighten to 355 Nm (262 ft. lbs.)
26. Install the coil wire pin to the electrical connector.
^ Install the coil wire pin (pin 16).
^ Install the connector interlock.
27. Install the transfer case in the vehicle.
28. Fill the transfer case.