Transfer Case Disassembly
- Remove front and rear output flange nuts, washers and flanges from front and rear output shafts. Remove speed sensor, 4WD indicator switch, rear bearing retainer bolts and retainer. See Fig 1
or Fig 2
.NOTE: Case-half screws are self-tapping screws and aluminum shavings are common when removed.
- Remove speedometer tone wheel, tone wheel snap ring and rear output bearing snap ring from mainshaft. Remove case screws and pry front case half from rear case half.
- Remove clutch coil connector, clutch coil nuts and clutch coil from rear case half. Remove shift rail spring from shift rail. Remove clutch coil housing snap ring and housing from mainshaft.
- Remove synchronizer hub from synchronizer assembly. Remove synchronizer assembly from mainshaft drive gear and mode shift fork from shift rail. Remove front output shaft snap ring and washer from shaft. See Fig 1 or Fig 2 .
- Remove drive gear, driven gear and drive chain as an assembly. Remove front output shaft, mainshaft and oil pump assembly. Remove shift rail, range fork and shift hub from input carrier assembly.
- Remove annulus gear snap ring, annulus gear and mainshaft front oil seal from front case. Remove carrier assembly snap ring from carrier assembly input shaft. Remove input carrier assembly and power take-off drive gear from front case.
- Remove retaining clip and sector shaft from front case. Remove sector, detent spring, detent roller and front input bearing snap ring and bearing from front case.
- Remove rear output bearing and front output shaft rear bearing from rear case. Remove front output shaft seal, front output bearing snap ring and front output bearing from front case. Remove rear output shaft seal from rear bearing retainer.