Transfer Case Disassembly
- Remove front companion flange, nut and washer. Remove 4WD indicator switch. Remove speedometer sensor. Remove poppet screw, spring and range selection plunger. See Fig 1 .
- Remove rear extension housing. Remove rear bearing retainer housing from mainshaft. Remove snap ring and bearing from housing. Remove speedometer gear snap ring and gear from mainshaft. Remove oil pump. Separate rear case from front case. Remove oil pump pick-up tube, filter and magnetic washer. Remove mode fork spring.
- Remove snap ring from driven sprocket. Remove mainshaft, drive chain and driven sprocket as a unit from front case. Mode fork and shift rail will come out with mainshaft. Remove synchronizer retaining snap ring. Remove synchronizer assembly and drive sprocket from mainshaft. Remove drive sprocket needle bearing.NOTE: It is NOT necessary to disassemble synchronizer assembly unless wear or damage is visible.
- Remove synchronizer stop ring and insert springs. Separate synchronizer sleeve from synchronizer hub. Ensure synchronizer inserts are not lost when synchronizer sleeve is removed. Remove range fork, range sector, mode fork and range shift hub. See Fig 1 or Fig 2 . On manual shift model, remove range shift lever, washer and nut. On electronic shift models, remove shift motor.
- On all models, remove input bearing retainer bolts and retainer. Remove retainer oil seal. Remove input gear lock ring. Remove planetary assembly and input gear. Remove input gear snap ring, carrier lock ring, thrust washer and bearing.
- Remove mainshaft pilot bearing from input gear. Remove front output bearing snap ring and bearing. Remove front output shaft oil seal. Remove oil seal from extension housing. Remove rear case needle bearing.