Transfer Case Clutch: Removal
WARNING: This page is about a different variant/trim than selected.
- Remove the transfer case. Refer to: Transfer Case .
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NOTE: Seal all openings before cleaning the transfer case exterior. This will prevent entry of dirt and water, which may cause damage to internal components.
Clean the transfer case with solvent and dry with compressed air.
- Using a transmission adjustable mounting arm, secure the transfer case to the bench. Use the General Equipment: Adjustable Mounting Arm
- Remove the transfer case rear seal. Refer to: Transfer Case Rear Seal .
- Disconnect the electrical connector and wiring harness retainer.
- Remove the retainers and wiring harness.
- Remove the transfer case bolts.
- Using the pry bosses, separate the transfer case covers.
- Remove the transfer case dowel pins.
- Remove the magnet from its slot in the case.
- Remove the snap ring.
- Remove the thrust washer.
- Remove the thrust bearing.
- Remove the thrust washer
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NOTE: Remove the drive chain and sprockets as an assembly.
Remove the drive chain and sprockets.
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NOTE: When removing the clutch pack assembly, do not separate the clutch pack assembly. Keep tension on the clutch pack during removal. Set the clutch pack assembly on the bench in the same position as located in the transfer case. The thrust washer in the lower clutch pack uses tabs to hold it in place. If the thrust washer is not in place, a transfer case clearance problem will occur.NOTE: If the clutch pack is disassembled, a new clutch pack and armature must be installed. Failure to install a new clutch pack can result in component failure.
Remove the clutch pack assembly with the armature.