Transfer Case Disassemble
TRANSFER CASE DISASSEMBLE^ TOOLS REQUIRED
- J22912-01 Bearing Puller
- J29369-1 Bushing and Universal Remover
- J44873 Shoulder Bolts
- J44879 Right Differential Installer
- J44882 Pinion Press Support Bar
1. Remove bolts from bracket (1).
2. Remove bracket (1).
3. Remove drain plug (1).
4. Remove the fill plug (1) and drain the fluid.
5. Install Shoulder Bolts J44873 and the attaching bolts to the pinion flange.
6. Using a breaker bar and a ratchet with a 27 mm socket, remove the pinion nut.
7. Insert Flange and Pulley Holding Tool J8614-2 (1) through the slots in Shoulder Bolts J44873 (2).
8. Turn the blue collar until it locks into the grooves on the underside of the Shoulder Bolts J44873.
IMPORTANT: Use high pressure grease on the screw threads.
9. Tighten the forcing screw to remove the pinion flange.
10. Remove Shoulder Bolts J44873 (2), the attaching bolts, and the Flange and Pulley Holding Tool J8614-2 (1) from pinion flange.
11. Remove all bolts (2) from the side cover (1).
12. Use pry point relief slots to remove the cover.
13. Remove the carrier assembly (1) from the housing.
IMPORTANT: The ring gear bolts must be removed first.
14. Using Right Differential Installer J44879 and Bearing Puller J22912-01, position the carrier into a press in order to remove the right side bearing.
15. Using Right Differential Installer J44879 and Bearing Puller J22912-01, position the carrier into a press in order to remove the left side bearing.
IMPORTANT:
^ The ring gear bolts have left hand threads.
^ Ring gear bolts are NOT to be reused. Install NEW ring gear bolts during assembly.
16. Remove the bolts (1) from the ring gear.
17. Remove the ring gear (1) from carrier (2).
18. Using Busing and Universal Remover J29369-1, remove the stub shaft inner bearing (2) from the carrier (1).
19. Remove the oil seal (1) from the housing.
IMPORTANT: It may be necessary to heat the housing in order to remove the bearing race.
20. Remove the bearing race (1), shims (2) and seal (3) from the side cover (4).
Mark or tag the bearing race and shims for assembly.
21. Remove the axle seal (2) from the side cover (1).
IMPORTANT: It may be necessary to heat the housing in order to remove the bearing race.
22. Remove the bearing race (2) and shim (1) from housing.
Mark or tag the bearing race and shims for assembly.
23. Remove the vent baffle.
24. Remove the oil seal (1) and slinger washer (2) from the housing.
NOTICE: Do not use air tools. The use of air tool will damage the Pinion Press, Support Bar J44882.
IMPORTANT: Use high pressure grease on threads of forcing screw.
25. Using the bolts supplied, attach Pinion Press Support Bar J44882 to carrier housing.
26. Tighten the forcing screw in order to push out the pinion gear. The gear will spin when it is being pushed out. When the gear stops spinning, stop pushing. The gear teeth will contact the housing.
27. Remove Pinion Press Support Bar J44882.
28. Install the old pinion nut on the threads of the pinion shaft. Hold the shaft so the gear head faces up, and drive out the pinion shaft, so that it does not contact the housing.
29. Remove the bearing (1), collapsible spacer (2), and pinion shaft (3) from the housing.
30. Install Bearing Puller J22912~1 (1) onto the pinion shaft.
31. Position the pinion shaft into a press in order to remove the bearing.
32. Remove the bearing (1) and shim (2) from the pinion shaft (3).
IMPORTANT:
^ Remove the baffle (2) before heating the housing.
^ It may be necessary to hear the housing in order to remove the bearing races. Do not heat the housing over 121°C (250°F).
33. Remove the inner and outer bearing races (1 and 2) from the housing.