Transfer Case Disassembly
NOTE:
See Fig 1
for exploded view of transfer case.
- Position transfer case on shallow drain pan. Remove drain plug and drain any remaining fluid. Remove and discard yoke flange nut, washer and rubber seal from front output shaft. Remove front output yoke. Remove 4WD actuator switch and "O" ring, then remove VSS and "O" ring. Remove detent plug, "O" ring, detent spring and detent pin from side of case.
- Remove rear extension housing bolts. Remove rear extension housing. Remove rear bearing retainer snap ring from mainshaft. Remove pump retainer housing bolts (bolts are shouldered). Loosen and remove pump retainer housing with pry bar placed under flange.
- Remove speedometer tone wheel snap ring from mainshaft. Remove tone wheel. Remove rear tone wheel snap ring. Remove bolts retaining case halves, noting and marking positions of 2 longer bolts and washers. Carefully pry case halves apart with 2 screwdrivers in cast slots on case ends. Remove rear case half and oil pump as an assembly, using care not to damage oil pump during removal.
- Remove oil pump from pickup tube and rear case half. Remove pickup tube, "O" ring and pickup filter from rear case half. Remove mode fork shift spring from shift rail.
- Remove snap ring from front output shaft. Remove mainshaft, drive chain and driven sprocket as an assembly from front case half. Note location of chain master link. Mode fork and shift rail will be removed with mainshaft. See Fig 1 .
- Remove snap ring retaining synchronizer to mainshaft. Remove synchronizer assembly. Remove drive sprocket from mainshaft.
- Rotate sector with shaft to obtain clearance when removing range fork. Remove range shift fork and shift hub and shaft from planetary carrier. See Fig 1 . From front case half, remove shift lever nut, washer, shift lever, sector, shaft assembly, plastic washer and "O" ring. Remove input bearing 3 retainer bolts and input bearing retainer.
- Remove input gear snap ring and input bearing snap ring. With soft-face hammer, remove planetary carrier and input gear from annulus gear. Remove input gear-to-planetary carrier snap ring. Remove input gear from planetary carrier. Use bearing remover to remove input bearing from front case half. Check needle bearings for damage.
- Remove mainshaft pilot bearing from input gear. Remove front output bearing snap ring. Remove front output shaft seal from front case half. Remove front output bearing from front case half. Remove seal from mainshaft extension housing. Remove seal from input bearing retainer.
- Remove front output bearing from rear case half. Remove mainshaft bearing from rear retainer housing. Remove magnet from case.
- If necessary to disassemble synchronizer assembly, mark location of synchronizer sleeve to hub for reassembly reference. Remove main drive synchronizer stop ring from synchronizer sleeve. Remove 2 spring retainers from synchronizer hub. Using care not to damage synchronizer struts, remove synchronizer hub from sleeve.