Transfer Case Disassemble

Transfer Case Disassemble

Special Tools
* J-46001 - Differential Drive Pinion Holding Tool
* J-46003 - Output Shaft Bearing Locknut Wrench




1. Remove the transfer and transaxle setting stud bolts (1-4).




2. Remove the number 2 transfer case plug (1).
3. Remove the gasket from the number 2 transfer case plug.




4. Remove the number 1 transfer case plug (1).
5. Remove the gasket from the number 1 transfer case plug.




6. Remove the transfer drain plug (1).
7. Remove the gasket from the transfer drain plug.




8. Using a screwdriver, remove the transfer case breather plug (1).




9. Remove the bolts (1-8).





Note: Place the brass bar on the rib part of the case.

10. Using a brass bar and a hammer, remove the number 1 transfer case cover from the transfer case.




11. Remove the bolt (1) and breather oil deflector.




12. Remove the bolts (1-3) and transfer dynamic damper from the transfer extension housing sub-assembly.




13. Remove the transfer case straight pins (1, 2) from the transfer case.




14. Install the transfer case onto the holding fixture through the straight pin locations (1, 2).




15. Using a plastic hammer, remove the transfer extension housing dust deflector from the transfer extension housing sub-assembly.




16. Using a suitable puller, remove the transfer case rear oil seal from the transfer extension housing sub-assembly.




17. Remove the bolts (1-4).




18. Using a plastic hammer, remove the transfer extension housing sub-assembly from the transfer case.
19. Using J-46003 - output shaft bearing locknut wrench and a torque wrench, measure the preload of the backlash between the driven pinion and ring gear.

* 0.39-0.69 Nm (3.5-6.1 lb in)
* 0.28-0.50 Nm (2.5-4.4 lb in)




20. Inspect the ring gear backlash.
21. Inspect the tooth contact between ring gear and drive pinion.
22. Coat 3 or 4 teeth at 4 different positions on the ring gear with red lead.




23. Rotate the ring gear to inspect the tooth pattern.




24. Using a suitable puller, remove the transfer case front oil seal from the transfer case.




25. Using a suitable puller (1), remove the transfer case front oil seal from the transfer case.




26. Remove the bolts (1, 2) and the bearing cap.
27. Remove the number 1 transfer output shaft spacer.
28. Remove the number 2 transfer ring gear mounting case washer.




29. Remove the transfer ring gear mounting case from the transfer case.




30. Remove driven pinion.
31. Unstake the gear nut using a hammer (1) and chisel.




32. Using J-46003 - wrench (2) and J-46001 - differential drive pinion holding tool (1), remove the gear nut.




33. Using a press, press out the driven pinion, transfer driven pinion rear bearing (inner race) and transfer pinion bearing spacer.




34. Using a press (1), press out the transfer driven pinion front bearing (inner race).





Note: Place the brass bar at the 2 positions of the cutouts on the case.

35. Using a brass bar and a hammer, tap the driven pinion front bearing (outer race) to remove from the case.
36. Remove the transfer output shaft washer.
37. Remove the ring gear mounting case bearing right side (outer race) from the transfer ring gear mounting case.
38. Using a suitable puller, remove the ring gear mounting case bearing right side (inner race) from the transfer ring gear mounting case.
39. Using a suitable puller, remove the ring gear mounting right side (inner race) RH from the transfer ring gear mounting case.





Note: Place the brass bar at the 2 positions of the cutouts on the case.

40. Using a brass bar and a hammer, tap the 2 positions of the ring gear mounting case bearing left side (outer race) to remove from the transfer case.
41. Remove the ring gear mounting case plate washer.
42. Inspect the runout of the ring gear.




43. Remove the ring gear.
44. Put matchmarks on the transfer ring gear mounting case and ring gear.
45. Remove the bolts (1-10).





Note: Do not damage the tooth surface of the ring gear.

46. Using a plastic hammer, tap on the ring gear to separate it from the transfer ring gear mounting case.
47. Inspect the transfer ring gear mounting case.





Note: Place the brass bar at the 2 positions of the cutouts on the case.

48. Using a brass bar and a hammer, tap the 2 positions on the driven pinion rear bearing (outer race) before removing it from the transfer case.




49. Using J-46003 - wrench and a torque wrench, measure the preload of the backlash between the driven pinion (1) and ring gear.

* 0.39-0.69 Nm (3.5-6.1 lb in)
* 0.28-0.50 Nm (2.5-4.4 lb in)

Use a torque wrench with a fulcrum length of 130 mm (5.12 in)
50. Using J-46003 - wrench and a torque wrench, measure the total preload.

* 0.25-0.44 Nm (2.2-3.9 lb in)
* 0.18-0.32 Nm (1.6-2.8 lb in)

Use a torque wrench with a fulcrum length of 130 mm (5.12 in)





Note: Check at least 3 positions on the circumference of the ring gear.

51. Using a dial gauge, check the backlash of the ring gear.

Backlash: 0.10-0.18 mm (0.0039-0.007 in)
If the backlash is not within the specification, adjust the side bearing preload or repair as necessary.




52. Inspect the tooth contact between the ring gear and drive pinion.
53. Coat 3 or 4 teeth at the 4 different positions on the ring gear with red lead.




54. Rotate the ring gear to inspect the tooth pattern.




55. Inspect the runout of the ring gear.

* Place the transfer ring gear mounting case on the V-block.
* Using a dial gauge, check the runout of the ring gear.

Maximum runout: 0.06 mm (0.0024 in)




56. Inspect the transfer ring gear mounting case.

* Place the transfer ring gear mounting case on the V-block.
* Using a dial gauge, check the runout of the ring gear.

Maximum runout: 0.04 mm (0.0016 in)