Special Tools
- DT-3289 - 20 Holding Fixture
- DT - 49308 Stud Remover and Installer
- J - 36842 Transaxle Holding Fixture
- J-45124 Removal Bridge
- J-45124 - 9 Puller Leg
- J-29369 - 2 Bushing and Bearing Remover - 2 - 3 in
Equivalent regional tools: Special Tools
Transfer Case Vibration Dampener Bolt (1) - Remove and DISCARD - { If equipped }
- Transfer Case Vibration Dampener (2) - Remove - { If equipped }
Use M10 x 1.5 mm nuts and bolts to retain the assembly to the fixture.
- J - 36842 Transaxle Holding Fixture (1) - Install @ Transfer Case (3)
- Attached transfer case and J - 36842 Transaxle Holding Fixture (1) to the DT-3289 - 20 Holding Fixture (2).
Remove and DISCARD the 2 transfer case front output shaft boot clamps (1).
- Transfer Case Front Output Shaft Boot (2) - Remove
- Transfer Case Vent (3) - Remove and DISCARD
- Use DT - 49308 Stud Remover and Installer (5) @ Transfer Case Stud (4) - Remove and DISCARD
Transfer Case Oil Fill Plug (1) - Remove and DISCARD
- Transfer Case Oil Drain Plug (3) - Remove and DISCARD
- Transfer Case Fluid Temperature Sensor (4) - Remove
- CAUTION:
Refer to Machined Surface Damage Caution .
Transfer Case Rear Output Shaft Oil Slinger (1) - Remove and DISCARD
- Transfer Case Rear Output Shaft Seal (2) - Remove and DISCARD
Transfer Case Half Bolt (1) - Remove and DISCARD [15x]
- Separate the case halves using a pry bar at the pry point locations.
- Remove the transfer case rear case half (2) from the transfer case front case half (3).
Transfer Case Output Shaft Ring (1) - Remove and DISCARD
- Transfer Case Output Shaft (2) - Remove
- Transfer Case Front Output Shaft Oil Slinger (3) - Remove and DISCARD
Remove the connector wire retaining clip (1) and separate the wires from the connector.
- Conduit (2) - Remove
- Transfer Case Access Hole Plug (3) - Remove [2x]
Transfer Case Two/Four Wheel Drive Clutch Coil Nut (1) - Remove and DISCARD [3x]
- Transfer Case Two/Four Wheel Drive Clutch Coil (2) - Remove
Transfer Case Oil Separator Bolt (1) - Remove and DISCARD [4x]
- Transfer Case Separator Plate (2) - Remove
- Transfer Case Oil Pump Screen (3) - Remove
- Transfer Case Half Locating Pin (4) - Remove [2x]
Transfer Case Oil Pump Retaining Ring (1) - Remove and DISCARD
- Inlet Pump Port (2) - Remove
- Transfer Case Oil Pump (3) - Remove
- Transfer Case Oil Pump Shaft (4) - Remove
Assemble special tools J-29369 - 2 Bushing and Bearing Remover - 2 - 3 in (4), J-45124 Removal Bridge (2), J-45124 - 9 Puller Leg (3), to remove the bearing.
- Transfer Case Front Output Shaft Rear Bearing (1) - Remove
Use special tools J-29369 - 2 Bushing and Bearing Remover - 2 - 3 in (4), J-45124 Removal Bridge (2), J-45124 - 9 Puller Leg (1), to remove the bearing.
- Transfer Case Rear Output Shaft Rear Bearing (1) - Remove
Transfer Case Rear Output Shaft Rear Bearing Retaining Ring (1) - Remove and DISCARD
- Transfer Case Four Wheel Drive Clutch Shim (2) - Remove
- Transfer Case Four Wheel Drive Clutch Housing Bearing (3) - Remove
- Transfer Case Two/Four Wheel Drive Clutch Coil Housing (4) - Remove
- Cam (1) - Remove
- Transfer Case Scissor Lever Ball (2) - Remove [3x]
- Transfer Case Scissor Mechanism Lever (3) - Remove
- Transfer Case Four Wheel Drive Clutch Pressure Plate Spring (4) - Remove
Transfer Case Two/Four Wheel Drive Clutch Retaining Ring (1) - Remove and DISCARD
- Transfer Case Armature (2) - Remove
- Transfer Case High/Low Clutch (3) - Remove
- Transfer Case Front Output Shaft Driven Sprocket Spacer (4) - Remove
Transfer Case Input Shaft Gear (1) - Remove
- Transfer Case Front Output Shaft Drive Sprocket Spacer (2) - Remove [2x]
- Transfer Case Front Output Shaft Drive Sprocket Bearing (3) - Remove [2x]
- NOTE:
The case halves, idler gear, and idler gear bearings and races are not available as separate service parts. If component replacement is required, the transfer case is to be replaced as an assembly.
Transfer Case Idler Gear (1) - Remove
- Transfer Case Front Output Shaft Gear (2) - Remove
Transfer Case Input Shaft Washer (1) - Remove
- Transfer Case Front Output Shaft Drive Sprocket Bearing (2) - Remove
- Transfer Case Vent Baffle Bolt (3) - Remove and DISCARD
- Transfer Case Vent Baffle (4) - Remove
- NOTE:
Spread the input shaft front bearing retainer ring to remove the input shaft.
Transfer Case Input Shaft (1) - Remove
- Transfer Case Input Shaft Bearing (2) - Remove
- Transfer Case Input Shaft Bore Plug (3) - Remove
Assemble special tools J-29369 - 2 Bushing and Bearing Remover - 2 - 3 in (4), J-45124 Removal Bridge (2), J-45124 - 9 Puller Leg (3), to remove the bearing.
- Transfer Case Front Output Shaft Front Bearing (1) - Remove
Transfer Case Front Output Shaft Seal (1) - Remove and DISCARD
- Transfer Case Input Shaft Seal (2) - Remove and DISCARD
Always secure with the pivot pin after rotating.
Remove the vent as required. If vent removal is required, install a NEW vent during assembly.
Remove the transfer case-to-transmission studs as required.
Remove the pins only as required.
If the clutch pack assembly is replaced, reprogramming of the transfer case module is required. K69 Transfer Case Control Module: Programming and Setup .
The orientation and of the gear and the location of the front output shaft snap ring groove for assembly. The gear is to be installed with the front output shaft snap ring groove facing away from the front case half.