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Service Information: Disassembly

WARNING: This page is about a different car, the 2005 Jeep Grand Cherokee. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Fill/Drain Plug And I.D. Tag Locations
GC0027439Courtesy of DAIMLERCHRYSLER CORP.
1 - FILL PLUG
2 - DRAIN PLUG
3 - SHIFT MOTOR AND MODE SENSOR ASSEMBLY
  1. Place the transfer case in a shallow pan and remove the fill (1) and drain (2) plugs to drain the remainder of the fluid. See Fig 1.
    Fig 2: Remove/Install Rear Output Shaft Nut
    GC0027440Courtesy of DAIMLERCHRYSLER CORP.
    1 - HOLDER C-3281
    2 - REAR COMPANION FLANGE
  2. Using Holder C-3281 (1), remove the rear companion flange (2) nut. See Fig 2.
    Fig 3: Remove/Install Rear Output Shaft Flange
    GC0027441Courtesy of DAIMLERCHRYSLER CORP.
    1 - REAR COMPANION FLANGE
    2 - OUTPUT SHAFT
  3. Remove the rear output shaft flange (1) from the output shaft (2). If necessary, use a suitable 2 or 3 jaw puller to remove the output shaft flange. See Fig 3.
    Fig 4: Remove/Install Shift Motor Bolts
    GC0027442Courtesy of DAIMLERCHRYSLER CORP.
    1 - BOLTS
    2 - SHIFT MOTOR AND MODE SENSOR ASSEMBLY
  4. Remove the bolts (1) holding the shift motor and mode sensor assembly (2) to the transfer case. See Fig 4.
    Fig 5: Remove/Install Shift Motor
    GC0027443Courtesy of DAIMLERCHRYSLER CORP.
    1 - SHIFT MOTOR AND MODE SENSOR ASSEMBLY
    2 - SHIFT SECTOR
    3 - TRANSFER CASE
  5. Remove the shift motor and mode sensor assembly (1) from the shift sector (2) and the transfer case (3). See Fig 5.
    Fig 6: Remove/Install Rear Retainer Bolts
    GC0027444Courtesy of DAIMLERCHRYSLER CORP.
    1 - REAR HOUSING
    2 - REAR COVER
    3 - BOLTS
  6. Remove the bolts (3) holding the rear cover (2) onto the rear housing (1). See Fig 6.
    Fig 7: Remove/Install Rear Retainer
    GC0027445Courtesy of DAIMLERCHRYSLER CORP.
    1 - REAR COVER
    2 - REAR HOUSING
  7. Remove the rear cover (1) from the rear housing (2). See Fig 7.
    Fig 8: Remove/Install Sector Roller Roll-pin
    GC0027446Courtesy of DAIMLERCHRYSLER CORP.
    1 - REAR HOUSING
    2 - ROLL-PIN
    3 - SHIFT RAIL
    4 - SECTOR ROLLER
  8. Using a suitable punch, remove the roll-pin (2) holding the sector roller (4) to the shift rail (3). See Fig 8.
    Fig 9: Remove/Install Sector Roller
    GC0027447Courtesy of DAIMLERCHRYSLER CORP.
    1 - SECTOR ROLLER
    2 - SHIFT RAIL
  9. Remove the sector roller (1) from the shift rail (2). See Fig 9.
    Fig 10: Remove/Install the Anti-Rotation Bracket
    GC0027448Courtesy of DAIMLERCHRYSLER CORP.
    1 - ANTI-ROTATION BRACKET
    2 - SHIFT RAIL
  10. Remove the anti-rotation bracket (1) from the shift rail (2). See Fig 10.
    Fig 11: Remove/Install Clutch Lever Rail Plug
    GC0027449Courtesy of DAIMLERCHRYSLER CORP.
    1 - CLUTCH LEVER RAIL PLUG
  11. Remove the clutch lever rail plug (1) from the rear housing. See Fig 11.
    Fig 12: Remove/Install Clutch Lever Rail
    GC0027450Courtesy of DAIMLERCHRYSLER CORP.
    1 - REAR HOUSING
    2 - CLUTCH LEVER RAIL
  12. Remove the clutch lever rail (2) from the rear housing (1). See Fig 12.
    Fig 13: Remove/Install Oil Pump Inner Rotor
    GC0027452Courtesy of DAIMLERCHRYSLER CORP.
    1 - OUTPUT SHAFT
    2 - OIL PUMP INNER ROTOR
    3 - REAR HOUSING
  13. Remove the oil pump inner rotor (2) from the output shaft (1) and rear housing (3). See Fig 13.
    Fig 14: Remove/Install Oil Pump Outer Rotor
    GC0027453Courtesy of DAIMLERCHRYSLER CORP.
    1 - OUTPUT SHAFT
    2 - OIL PUMP OUTER ROTOR
    3 - REAR HOUSING
  14. Remove the oil pump outer rotor (2) from the output shaft (1) and rear housing (3). See Fig 14.
    Fig 15: Remove/Install Rear Housing Bolts
    GC0027451Courtesy of DAIMLERCHRYSLER CORP.
    1 - REAR HOUSING
    2 - BOLTS
    3 - FRONT HOUSING
  15. Remove the bolts (2) holding the rear housing (1) to the front housing (3). See Fig 15.
    Fig 16: Remove/Install Rear Output Bearing Inner Retaining Ring
    GC0027454Courtesy of DAIMLERCHRYSLER CORP.
    1 - OUTPUT SHAFT
    2 - RETAINING RING
    3 - REAR HOUSING
  16. Remove the rear output shaft (1) retaining ring (2). See Fig 16.
    Fig 17: Remove/Install Rear Housing
    GC0027455Courtesy of DAIMLERCHRYSLER CORP.
    1 - REAR HOUSING
    2 - FRONT HOUSING
  17. Remove the rear housing (1) from the front housing (2). See Fig 17.
    Fig 18: Remove/Install Clutch Lever Assembly
    GC0027456Courtesy of DAIMLERCHRYSLER CORP.
    1 - CLUTCH LEVER ASSEMBLY
  18. Remove the clutch lever assembly (1) from the mainshaft and shift rail. See Fig 18.
    Fig 19: Remove/Install Thrust Bearing Support Plate Retaining Ring
    GC0027457Courtesy of DAIMLERCHRYSLER CORP.
    1 - OUTPUT SHAFT
    2 - RETAINING RING
  19. Remove the thrust bearing support plate retaining ring (2) from the output shaft (1). See Fig 19.
    Fig 20: Remove/Install Thrust Bearing Support Plate
    GC0027458Courtesy of DAIMLERCHRYSLER CORP.
    1 - OUTPUT SHAFT
    2 - SUPPORT PLATE
  20. Remove the thrust bearing support plate (2) from the output shaft (1). See Fig 20.
    Fig 21: Remove/Install Thrust Bearing
    GC0027459Courtesy of DAIMLERCHRYSLER CORP.
    1 - OUTPUT SHAFT
    2 - THRUST BEARING
  21. Remove the thrust bearing (2) from the output shaft (1). See Fig 21.
    Fig 22: Remove/Install Clutch Pressure Plate
    GC0027460Courtesy of DAIMLERCHRYSLER CORP.
    1 - OUTPUT SHAFT
    2 - CLUTCH PRESSURE PLATE
  22. Remove the clutch pressure plate (2) from the output shaft (1) and clutch assembly. See Fig 22.
    Fig 23: Remove/Install Wavy Spring Assembly
    GC0027461Courtesy of DAIMLERCHRYSLER CORP.
    1 - OUTPUT SHAFT
    2 - WAVY SPRING
  23. Remove the wave spring (2) from the output shaft (1). See Fig 23.
    Fig 24: Remove/Install Clutch Assembly
    GC0027462Courtesy of DAIMLERCHRYSLER CORP.
    1 - OUTPUT SHAFT
    2 - CLUTCH ASSEMBLY
  24. Remove the clutch assembly (2) from the output shaft (1). See Fig 24.
    Fig 25: Remove/Install Front Drive Sprocket Retaining Ring
    GC0027414Courtesy of DAIMLERCHRYSLER CORP.
    1 - FRONT OUTPUT SHAFT
    2 - RETAINING RING
  25. Remove the front output shaft (1) drive sprocket retaining ring (2). See Fig 25.
    Fig 26: Remove/Install Front and Rear Drive Sprockets and Drive Chain
    GC0027463Courtesy of DAIMLERCHRYSLER CORP.
    1 - FRONT DRIVE SPROCKET
    2 - MAINSHAFT DRIVE SPROCKET
    3 - DRIVE CHAIN
  26. Remove the front drive sprocket (1), mainshaft drive sprocket (2), and drive chain (3) as one. See Fig 26.
    Fig 27: Remove/Install Chain Guide Bolts
    GC0027464Courtesy of DAIMLERCHRYSLER CORP.
    1 - CHAIN GUIDE RAIL
    2 - SCREWS
  27. Remove the screws (2) holding the chain guide rails (1) to the front housing. See Fig 27.
    Fig 28: Remove/Install Chain Guide
    GC0027465Courtesy of DAIMLERCHRYSLER CORP.
    1 - DRIVE CHAIN GUIDE
  28. Remove the drive chain guides (1) from the transfer case. See Fig 28.
    Fig 29: Remove/Install Mainshaft and Differential Assembly
    GC0027466Courtesy of DAIMLERCHRYSLER CORP.
    1 - MAINSHAFT AND DIFFERENTIAL ASSEMBLY
    2 - FRONT HOUSING
  29. Remove the mainshaft and differential assembly (1) from the front housing (2). See Fig 29.
    Fig 30: Intermediate Clutch Shaft Snap-Ring
    GC0006004Courtesy of DAIMLERCHRYSLER CORP.
    1 - SNAP-RING
    2 - INTERMEDIATE CLUTCH SHAFT
  30. Remove intermediate clutch shaft (2) snap-ring (1). See Fig 30.
    Fig 31: Intermediate Clutch Shaft Thrust Ring
    GC0006005Courtesy of DAIMLERCHRYSLER CORP.
    1 - CLUTCH SHAFT THRUST RING
  31. Remove the intermediate clutch shaft thrust ring (1). See Fig 31.
    Fig 32: Removing/Installing Intermediate Clutch Shaft
    GC0006006Courtesy of DAIMLERCHRYSLER CORP.
    1 - INTERMEDIATE CLUTCH SHAFT
  32. Remove the intermediate clutch shaft (1). See Fig 32.
    Fig 33: Removing/Installing Differential Snap Ring
    GC0006007Courtesy of DAIMLERCHRYSLER CORP.
    1 - DIFFERENTIAL SNAP-RING
  33. Remove the differential snap-ring (1). See Fig 33.
    Fig 34: Removing/Installing Differential
    GC0006008Courtesy of DAIMLERCHRYSLER CORP.
    1 - DIFFERENTIAL ASSEMBLY
    2 - MAINSHAFT
  34. Remove the differential assembly (1) from the mainshaft (2). See Fig 34.
    Fig 35: Removing/Installing Mode Hub and Retainer
    GC0006009Courtesy of DAIMLERCHRYSLER CORP.
    1 - DIFFERENTIAL ASSEMBLY
    2 - MODE HUB AND RETAINER
  35. Remove the mode hub (2) and mode hub retainer from the differential assembly (1). See Fig 35.
    Fig 36: Removing/Installing Retainer at Mode Hub
    GC0006010Courtesy of DAIMLERCHRYSLER CORP.
    1 - MODE HUB RETAINER
    2 - MODE HUB
  36. Remove the mode hub retainer (1) from the mode hub (2). See Fig 36.
    Fig 37: Remove/Install Range Fork and Sleeve
    GC0027467Courtesy of DAIMLERCHRYSLER CORP.
    1 - RANGE FORK
    2 - RANGE HUB
  37. Remove the range fork (1) and range hub (2) as one. See Fig 37.
    Fig 38: Remove/Install Front Output Shaft Retaining Ring
    GC0027420Courtesy of DAIMLERCHRYSLER CORP.
    1 - FRONT OUTPUT SHAFT
    2 - RETAINING RING
  38. Remove the retaining ring (2) from the front output shaft (1). See Fig 38.
    Fig 39: Remove/Install Front Output Shaft and Flange
    GC0027421Courtesy of DAIMLERCHRYSLER CORP.
    1 - FRONT HOUSING
    2 - FRONT OUTPUT SHAFT
  39. Remove the front output shaft (2) from the front housing (1) and the front output shaft front bearing. See Fig 39.
    Fig 40: Remove/Install Oil Pump Pick-up Tube and Screen
    GC0027469Courtesy of DAIMLERCHRYSLER CORP.
    1 - OIL PICK-UP TUBE AND SCREEN
  40. Remove the oil pick-up tube and screen (1) from the rear housing.
    Fig 41: Remove/Install Oil Pump Pick-up Tube O-ring
    GC0027470Courtesy of DAIMLERCHRYSLER CORP.
    1 - REAR HOUSING
    2 - O-RING
  41. Remove the oil pick-up tube o-ring (2) from the rear housing (1). See Fig 41.
    Fig 42: Remove/Install Sector Shaft Retaining Ring
    GC0027471Courtesy of DAIMLERCHRYSLER CORP.
    1 - SHIFT SECTOR
    2 - RETAINING RING
  42. Remove the retaining ring (2) from the shift sector shaft (1). See Fig 42.
    Fig 43: Remove/Install Sector Shaft
    GC0027472Courtesy of DAIMLERCHRYSLER CORP.
    1 - FRONT HOUSING
    2 - SHIFT SECTOR
  43. Remove the shift sector (2) from the front housing (1). See Fig 43.
    Fig 44: Removing/Installing Input Gear Retaining Ring
    GC0005865Courtesy of DAIMLERCHRYSLER CORP.
    1 - INPUT GEAR
    2 - RETAINING RING
  44. Remove the input shaft seal with a suitable pry tool or a screw mounted in a slide hammer.
  45. Remove the retaining ring (2) holding the input gear assembly into the front housing. See Fig 44.
    Fig 45: Remove/Install Input Planetary Assembly
    GC0027468Courtesy of DAIMLERCHRYSLER CORP.
    1 - INPUT GEAR AND LOW RANGE PLANETARY
  46. Remove the input gear and low range planetary assembly (1) from the front housing. See Fig 45.
    Fig 46: Remove/Install Low Range Snap-ring
    GC0027474Courtesy of DAIMLERCHRYSLER CORP.
    1 - INPUT GEAR
    2 - SNAP-RING
    3 - LOW RANGE PLANETARY
  47. Remove the snap-ring (2) holding the input gear (1) into the low range planetary (3). See Fig 46.
    Fig 47: Remove/Install Low Gear and Lock Plate
    GC0027475Courtesy of DAIMLERCHRYSLER CORP.
    1 - INPUT GEAR
    2 - LOCK PLATE
    3 - LOW RANGE PLANETARY
  48. Remove the input gear (1) and lock plate (2) from the low range planetary (3) and remove the lock plate. See Fig 47.
    Fig 48: Remove/Install Top Thrust Washer
    GC0027476Courtesy of DAIMLERCHRYSLER CORP.
    1 - INPUT GEAR
    2 - THRUST WASHER (NO TABS)
  49. Remove the top thrust washer (no tabs) (2) from the input gear (1). See Fig 48.
    Fig 49: Remove/Install Bottom Thrust Washer
    GC0027477Courtesy of DAIMLERCHRYSLER CORP.
    1 - BOTTOM THRUST WASHER (3 TABS)
    2 - LOW RANGE PLANETARY
  50. Remove the bottom thrust washer (3 tabs) (1) from the low range planetary (2). See Fig 49.
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