Shift Forks And MAINSHAFT

WARNING: This page is about a different car, the 2005 Jeep Liberty. However, it is still accessible from the selected car via links, so may be relevant.

Remove shift detent plug, spring and pin. See Fig 1.

Fig 1: Detent Plug, Spring, And Plunger

Courtesy of DAIMLERCHRYSLER CORP.

1 - PLUNGER

2 - O-RING

3 - PLUG

4 - SPRING

Remove seal plug from low range fork lock pin access hole. Then move shift sector to align low range fork lock pin with access hole.
Remove range fork lock pin with size number one easy-out tool as follows:
- Insert easy-out tool through access hole in side of transfer case and into lock pin.
- Tap easy-out tool into lock-pin with hammer until tool is securely engaged into the lock pin.
- Install a t-handle, such as from a tap and die set, onto the easy-out tool.
- Securely tighten the t-handle onto the tool.
- In one motion, pull upward and turn the t-handle counterclockwise to remove the lock pin.
Remove shift rail by pulling it straight up and out of fork. See Fig 2.
Remove mode fork and mainshaft as assembly. See Fig 3.

Remove mode shift sleeve and mode fork assembly from mainshaft. See Fig 4. Note position of mode sleeve in fork and remove sleeve.

Fig 2: Identifying Shift Rail

Courtesy of DAIMLERCHRYSLER CORP.

1 - SHIFT RAIL

2 - MODE FORK

Fig 3: Identifying Mainshaft And Mode Fork

Courtesy of DAIMLERCHRYSLER CORP.

1 - MAINSHAFT ASSEMBLY

2 - MODE FORK

Fig 4: Identifying Mode Fork And Sleeve

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1 - MAINSHAFT

2 - MODE SLEEVE

3 - MODE FORK ASSEMBLY

Remove intermediate clutch shaft snap-ring. See Fig 5.
Remove clutch shaft thrust ring. See Fig 6.
Remove intermediate clutch shaft. See Fig 7.

Fig 5: Identifying Intermediate Clutch Shaft Snap-Ring
Courtesy of DAIMLERCHRYSLER CORP.

1 - SNAP-RING

2 - INTERMEDIATE CLUTCH SHAFT

Fig 6: Identifying Clutch Shaft Thrust Ring
Courtesy of DAIMLERCHRYSLER CORP.

1 - CLUTCH SHAFT THRUST RING

Fig 7: Identifying Intermediate Clutch Shaft
Courtesy of DAIMLERCHRYSLER CORP.

1 - INTERMEDIATE CLUTCH SHAFT
Remove differential snap-ring. See Fig 8.
Remove differential. See Fig 9.
Remove differential needle bearings and both needle bearing thrust washers from mainshaft.

Fig 8: Identifying Differential Snap-Ring
Courtesy of DAIMLERCHRYSLER CORP.

1 - DIFFERENTIAL SNAP-RING

Fig 9: Remove the Differential
Courtesy of DAIMLERCHRYSLER CORP.

1 - DIFFERENTIAL

2 - MAINSHAFT
Slide low range fork pin out of shift sector slot.
Remove low range fork and sleeve. See Fig 10.
Remove shift sector.

Fig 10: Range Fork and Hub Removal
Courtesy of DAIMLERCHRYSLER CORP.

1 - RANGE HUB

2 - RANGE FORK
Remove the shift sector shaft seal. See Fig 11.
Remove the shift sector shaft bearing with an appropriate socket. See Fig 12.

Fig 11: Remove Shift Shaft Seal

Courtesy of DAIMLERCHRYSLER CORP.

1 - SHIFT SHAFT SEAL

2 - TRANSFER CASE

Fig 12: Remove/Install Shift Sector Shaft Bearing

Courtesy of DAIMLERCHRYSLER CORP.

1 - TRANSFER CASE

2 - SOCKET