Part 1
Transfer Case - 2-Speed Torque-On-Demand
Disassembly
1. Remove the transfer case.
2. Using the special tool, secure the transfer case to the bench.
3. Remove the 3 heat shield bolts, then remove the heat shield.
4. 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 lb-ft).
5. Using the special tool to hold the output flange, remove the rear output shaft flange nut.
6. Remove the output shaft yoke washer.
7. Using the special tool, remove the output flange.
8. Remove and discard the output flange oil seal.
9. Using the special tools, remove and discard the yoke-to-flange seal.
10. Remove the connector interlock. Using a electrical connector pin extractor tool, remove the coil wire pin from the electrical connector.
11. Remove the 4 transfer case shift motor bolts.
12. Remove the transfer case shift motor.
13. Remove the 17 transfer case bolts.
14. Remove the 3 clutch coil assembly nuts.
15. Separate the transfer case halves at the transfer case pry bosses.
16. Remove the snap ring, then using the special tool, remove the rear output shaft support bearing.
17. Using the special tool, remove the front output shaft rear bearing.
18. Remove the thrust bearing.
19. Remove the cam and coil housing assembly.
20. Remove the apply cam and 3 steel balls.
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 driven sprocket thrust washer.
25. Remove the drive chain and the 2 sprockets as an assembly.
26. Remove and clean the oil pan magnet.
27. Remove the thrust washer.
28. Remove the pump assembly and the rear output shaft as an assembly.
29. Remove the electric shift cam assembly. Do not disassemble 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 and discard 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. Using a drift and hammer, remove the output shaft bushing and bearing, if necessary.
35. If the planetary gear carrier support bearing removal is necessary, remove the snap ring.
36. Using a suitable press and the special tool, remove the planetary gear carrier support bearing.
37. Remove the planetary input shaft.
38. While holding the front output shaft and flange, remove the snap ring.
39. Remove the front output shaft and flange.
40. Using the special tools, remove and discard the oil seal.
41. Using the special tools, remove the front output shaft support bearing.
42. Remove and discard the shifter shaft seal.
