Transfer Case Disassemble

Tools Required

• DT-47752  Split Plate Set. See Special Tools .
• J-2619-A  Slide Hammer w/Adapter. See Special Tools .
• J 8107-2  Side Bearing Puller Pilot. See Special Tools .
• J 8433  Two Jaw Puller. See Special Tools .
• J 22888-20A  Universal Two Jaw Puller. See Special Tools .
• J 29369-1  Bushing and Bearing Remover. See Special Tools .

Fig 1: View Of Dampener
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1. Remove the bolts (16) and the dampener (300), some models .
Fig 2: Identifying Transfer Case Drain & Fill Plugs
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2. Remove the drain plug (8) and the fill plug (6). Ensure all transfer case fluid is drained out of the transfer case.
Fig 3: Locating Case Attaching Bolts
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IMPORTANT: To prevent thread damage, clean exposed bolt threads before removing bolts.
3. Remove the 17 case attaching bolts (11).
Fig 4: Identifying Pry Points On Transfer Case
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NOTE: Do not nick, scratch or damage the sealing surface. The sealing surface is a machined surface. Damage to the machined surface can cause leakage.
4. Using a screwdriver at the pry points located on the case (1) and cover (2), pry the case (1) and cover (2) apart.
Fig 5: View Of Case, Cover & Alignment Dowel
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5. Separate the case (1) and cover (2).
6. Remove the alignment dowel (3) from the case, if necessary.
Fig 6: View Of Chain Snubber
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7. Remove the chain snubber.
Fig 7: Installing DT-47752 Plate To Chain
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8. Install 1 plate of the DT-47752  perpendicular to the chain and rotate 180 degrees. See Special Tools .
Fig 8: Installing Second Plate & Bolts To Chain
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9. Install the second plate perpendicular to the chain and secure with the short plate bolts.
Fig 9: View Of DT-47752-2, J 8433 & Front Output Shaft
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10. Install the DT-47752-2 (2) onto the front output shaft (112).
11. Using the long bolts and washers from DT-47752  , install the J 8433  (1). See Special Tools . Tighten evenly so the puller remains parallel to the plates.
Fig 10: Tightening Forcing Screw Of DT-47752-2
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NOTE: Failure to support the input shaft and carrier during removal may bind and damage the chain.
12. Install DT-47752-3 into the input shaft.
13. Using an impact wrench, tighten the forcing screw of the DT-47752-2 in order to remove the sprockets, chain and carrier assembly.
Fig 11: View Of DT-47752-2, J 8433 & Front Output Shaft
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14. Remove the J 8433  (1) and the DT-47752-2 (2). See Special Tools .
Fig 12: View Of Lower Sprocket, Chain & Carrier
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IMPORTANT: If the chain and sprockets are to be used again, note the position of the blue chain link, in or out.
15. Remove the lower sprocket (112), chain (109) and carrier (111) as an assembly.
Fig 13: Removing DT-47752 From Case
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16. Remove the DT-47752  from the case. See Special Tools .
Fig 14: View Of Snap Ring, Front Output Shaft & Case
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17. Remove the snap ring (114).
18. Push the front output shaft (112) from the case (1).
Fig 15: View Of Vent Baffle & Bolt
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19. Remove the vent baffle bolt (9) and baffle (10) from the case (1).
Fig 16: View Of Front Input & Output Seals
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NOTE: Do not damage the sealing surfaces of the transfer cases or the shafts when prying the seals for removal. Damaging the sealing surface may cause leakage or require replacement of the damaged component.
20. Using a hammer and a suitable driver, remove the front output seal (13) and input seal (14) from the case (1).
Fig 17: Removing Front Output & Input Bearings
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IMPORTANT: Only remove the bearings if they are to be replaced.
21. Using a hammer and a suitable punch, remove the front output bearing (113) and input bearing (117) if they are to be replaced.
Fig 18: Locating Vent
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22. If required, remove the vent (15) and discard.
23. Replace it with a NEW vent.
Fig 19: View Of Thrust Washer & Carrier
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24. Remove the thrust washer (100) from the carrier (111).
Fig 20: Removing Input Shaft Assembly From Carrier
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25. Using a press, remove the input shaft assembly (118, 107 and 110) from the carrier (111).
Fig 21: View Of Carrier Assembly
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IMPORTANT: The carrier assembly (111) must be installed with the thrust washer and groove around the splines toward the output shaft. Reversing this will cause the wrong torque split of 60/40, on some models.
26. Note the direction of the carrier assembly (111). The groove around the splines for 50/50 and 40/60 ratios face towards the output shaft.
Fig 22: Removing Sun Gear Using J 22888-20A & J 8107-2
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27. Using the J 22888-20A  (1) and the J 8107-2  (2), remove the sun gear (101) from the rear output shaft. See Special Tools .
Fig 23: View Of Snap Ring, Output Shaft & Cover
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28. Using snap ring pliers, remove the snap ring (102) from the output shaft (106).
29. Push the output shaft (106) from the cover (2).
Fig 24: Removing Rear Output Seal & Outside Output Bearing
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NOTE: Do not damage the sealing surfaces of the transfer cases or the shafts when prying the seals for removal. Damaging the sealing surface may cause leakage or require replacement of the damaged component.
NOTE: Do not remove the bearings unless they will be replaced. Removing the bearings will damage the races.
30. Using a hammer and a suitable punch, from inside the cover, drive out the rear output seal (7) and the outside output bearing (104).
Fig 25: Removing Inner Output Shaft Bearing
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NOTE: Do not remove the bearings unless they will be replaced. Removing the bearings will damage the races.
31. Using a hammer and a suitable punch, from outside the cover (2), inside the output shaft bore, drive out the inner output shaft bearing (103).
Fig 26: Removing Output Cover Bearing From Cover
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NOTE: Do not remove the bearings unless they will be replaced. Removing the bearings will damage the races.
32. Using the J-2619-A  (1) and the J 29369-1  (2), remove the front output cover bearing (116) from the cover. See Special Tools .