Transfer Case MPT3015: Disassembly

DISASSEMBLY 

1. Remove the transfer case. Refer to REMOVAL AND INSTALLATION  .

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   1 - Shift Motor Mounting Bolts

   2 - Transfer Case Shift Motor

   3 - Rear Output Flange

   4 - Case Bolts

2. Remove the shift motor mounting bolts and shift motor.
   NOTE:

   Clean the Loctite™ from the threads with a thread chaser before installing new motor bolts. Installing new bolts with Loctite™ can cause the case to crack and damage the case half if the old Loctite™ sealer is not removed.

3. Remove the rear output flange nut and rear output flange spline seal.
4. Remove the rear output flange.
5. Remove the case bolts from the transfer case housing.

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   1 - Case Half Pry Points

6. Separate the case halves.
   NOTE:

   Carefully pry at the pry points on the case halves to break the seal.

7. Remove the rear oil deflector from the mainshaft.

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   1 - Clutch Assembly Snap Ring

8. DO NOT  remove the snap ring that is on the mainshaft under the rear deflector, holding the clutch and ball ramp assembly together. The mainshaft, clutch and ball ramp assembly cannot be serviced. Altering or replacing any of these parts will change the torque classification of the transfer case. If any of these components are damaged, the transfer case assembly must be replaced.

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   1 - Oil Deflector Tube

   2 - Locking Tabs

9. Carefully release the locking tabs holding the oil deflector tube in place. Remove the oil deflector tube from the deflector tank.
   NOTE:

   Be careful not to damage the deflector tube or tank. The parts are not available separately.

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   1 - Oil Tank Deflector

   2 - Oil Tank Deflector Cover Tabs

10. Carefully release the seven locking tabs and remove the top cover on the deflector tank. Use care not to break the tabs.
    NOTE:

    The tank will not come out around the mainshaft with the cover on.

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    1 - Oil Tank Deflector

11. Remove the deflector tank from the front case half.

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    1 - Snap Ring

    2 - Front Case Half

12. Using a long pair of snap ring pliers, spread the snap ring holding the mainshaft assembly in the front case half while lifting the mainshaft assembly from the case until it is free of the snap ring.
    NOTE:

    The input bearing will come out with the mainshaft.

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    1 - Front Output Gear

    2 - Mainshaft Assembly

    3 - Chain

13. Simultaneously remove the mainshaft assembly, chain and front output gear from the front case half.

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    1 - Front Output Shaft

    2 - Snap Ring

14. If necessary, remove the snap ring from the front output shaft and remove the output shaft from the transfer case.
    NOTE:

    This is necessary if the front output seal requires replacement.

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    1 - Input Shaft Seal

15. Use a suitable screwdriver and hammer to remove the input shaft seal from the inside of the case half.
    NOTE:

    The seal should be removed and replaced with a new seal after installation of the mainshaft assembly to avoid damaging the original seal on re-assembly.

16. If necessary, remove the rear output shaft seal.