MAINSHAFT, Front Output Shaft, And Drive Chain

WARNING: This page is about a different variant/trim than selected.

Note position of bolts that attach rear case to front case. Some bolts are unique. Mark position of these bolts with paint or scriber.
Remove rear case-to-front case bolts.

Fig 1: Removing Case Half Bolt
Courtesy of DAIMLERCHRYSLER CORP.
Loosen rear case with pry tool to break sealer bead.
Unseat rear case from alignment dowels.

Fig 2: Locating Case Alignment Dowel
Courtesy of DAIMLERCHRYSLER CORP.

CAUTION: Do not remove the bolts holding the oil pump cover to the rear case half. The oil pump cover is aligned to the rear output shaft bearing inner race and will become misaligned if the bolts are loosened. If the transfer case failure has generated any debris which may have become trapped in the oil pump, the rear case and oil pump assembly MUST be replaced.

Fig 3: Removing Rear Case Half

Courtesy of DAIMLERCHRYSLER CORP.

Remove rear case and oil pump assembly from front case.
Remove shift rail cups and spring.

Fig 4: Removing Shift Rail Cup & Spring
Courtesy of DAIMLERCHRYSLER CORP.
Remove front drive sprocket retaining ring.

Fig 5: Removing Front Drive Sprocket Snap Ring
Courtesy of DAIMLERCHRYSLER CORP.
Remove mainshaft, front sprocket, and chain as an assembly.

Fig 6: Removing Mainshaft, Drive Chain & Front Sprocket
Courtesy of DAIMLERCHRYSLER CORP.