Clutch Pack
WARNING: This page is about a different variant/trim than selected.
| 1 - FILL PLUG |
| 2 - DRAIN PLUG |
| 3 - SHIFT MOTOR AND MODE SENSOR ASSEMBLY |
- 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.
1 - HOLDER C-3281 2 - REAR COMPANION FLANGE - Using Holder C-3281 (1), remove the rear flange (2) nut. See Fig 2.
1 - REAR COMPANION FLANGE 2 - OUTPUT SHAFT - Remove the rear output flange (1) from the main shaft (2). If necessary, use a suitable 2 or 3 jaw puller to remove the output flange. See Fig 3.
1 - BOLTS 2 - SHIFT MOTOR AND MODE SENSOR ASSEMBLY - Remove the bolts (1) holding the shift motor and mode sensor assembly (2) to the transfer case. See Fig 4.
1 - SHIFT MOTOR AND MODE SENSOR ASSEMBLY 2 - SHIFT SECTOR 3 - TRANSFER CASE - Remove the shift motor and mode sensor assembly (1) from the shift sector (2) and the transfer case (3). See Fig 5.
1 - REAR HOUSING 2 - REAR COVER 3 - BOLTS - If necessary, remove the bolts holding the transfer case damper to the transfer case and remove the damper.
- Remove the bolts (3) holding the rear cover (2) onto the rear housing (1). See Fig 6.
1 - REAR COVER 2 - REAR HOUSING NOTE: Use the pry slots provided and take care not to damage the sealing surface. - Remove the rear cover (1) from the rear housing (2). See Fig 7.
1 - REAR HOUSING 2 - ROLL-PIN 3 - SHIFT RAIL 4 - SECTOR ROLLER NOTE: Rotate the sector upward to ease the removal of the roll-pin. - Using a suitable punch, remove the roll-pin (2) holding the sector roller (4) to the shift rail (3). See Fig 8.
1 - SECTOR ROLLER 2 - SHIFT RAIL - Remove the sector roller (1) from the shift rail (2). See Fig 9.
1 - ANTI-ROTATION BRACKET 2 - SHIFT RAIL - Remove the anti-rotation bracket (1) from the shift rail (2). See Fig 10.
1 - CLUTCH LEVER RAIL PLUG - Remove the clutch lever rail plug (1) from the rear housing. See Fig 11.
1 - REAR HOUSING 2 - CLUTCH LEVER RAIL - Remove the clutch lever rail (2) from the rear housing (1). See Fig 12.
1 - OUTPUT SHAFT 2 - OIL PUMP INNER ROTOR 3 - REAR HOUSING - Remove the oil pump inner rotor (2) from the main shaft (1) and rear housing (3). See Fig 13.
1 - OUTPUT SHAFT 2 - OIL PUMP OUTER ROTOR 3 - REAR HOUSING - Remove the oil pump outer rotor (2) from the main shaft (1) and rear housing (3). See Fig 14.
1 - OUTPUT SHAFT 2 - RETAINING RING 3 - REAR HOUSING NOTE: Pull upward on the main shaft to ease the removal of the main shaft retaining ring. - Remove the rear output shaft (1) retaining ring (2). See Fig 15.
1 - REAR HOUSING 2 - BOLTS 3 - FRONT HOUSING - Remove the bolts (2) holding the rear housing (1) to the front housing (3). See Fig 16.
1 - REAR HOUSING 2 - FRONT HOUSING NOTE: Some prying may be necessary to break the seal between the front and rear case. Use care to not damage the sealing surfaces. - Remove the rear housing (1) from the front housing (2). See Fig 17.
1 - CLUTCH LEVER ASSEMBLY - Remove the clutch lever assembly (1) from the mainshaft and shift rail. See Fig 18.
1 - OUTPUT SHAFT 2 - RETAINING RING - Remove the thrust bearing support plate retaining ring (2) from the main shaft (1). See Fig 19.
1 - OUTPUT SHAFT 2 - SUPPORT PLATE - Remove the thrust bearing support plate (2) from the main shaft (1). See Fig 20.
1 - OUTPUT SHAFT 2 - THRUST BEARING - Remove the thrust bearing (2) from the main shaft (1). See Fig 21.
1 - OUTPUT SHAFT 2 - CLUTCH PRESSURE PLATE - Remove the clutch pressure plate (2) from the main shaft (1) and clutch assembly. See Fig 22.
1 - OUTPUT SHAFT 2 - WAVY SPRING - Remove the wave spring (2) from the main shaft (1). See Fig 23.
1 - TOP (INNER TEETH) CLUTCH PLATE 2 - CLUTCH RETAINER - Remove the top (inner teeth) clutch plate (1) from the clutch retainer (2). See Fig 24.
1 - BOTTOM (OUTER LUGS) CLUTCH PLATE 2 - CLUTCH RETAINER - Continue removing clutch plates from the clutch retainer (2) until the bottom (outer lugs) clutch plate (1) is removed. Keep the discs in their original sequence if the discs are to be reused. See Fig 25.