Transfer Case MPT3028: Disassembly

DISASSEMBLY OF HOUSING AND REMOVAL OF SHAFTS 

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 - Transfer Case Position Sensor Bolts

   4 - Transfer Case Position Sensor

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

   Chase and clean the thread lock from the threads before installing the new bolts on re-assembly. Failure to do so can cause the case to crack and damage the case half when installing new bolts with thread lock.

3. Remove the transfer case position sensor bolts and position sensor.
4. Remove the rear output flange nut and output flange.

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   1 - Case Bolts

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.

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   1 - Spacer

7. Remove the spacer.
   NOTE:

   Note the orientation of the internal tabs of the spacer for reassembly purposes. The tabs are flat with the side facing up.

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   1 - Shift Shaft Rear Bearing

   2 - Worm Gear

   3 - Oil Pump Tube

   4 - Oil Pump

8. Remove the oil pump tube and magnet. Be careful not to damage the O-ring for the oil pump tube.
9. Remove the oil pump.
10. Remove the shift shaft rear bearing.
11. Remove the worm gear from the shift shaft.
    NOTE:

    Note that the concave side of the worm gear is facing up for reassembly purposes.

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    1 - Shift Shaft Assembly

    2 - Mainshaft/Clutch Assembly

    3 - Chain

12. Simultaneously remove the mainshaft/clutch assembly, shift shaft assembly, chain and front output gear from the front case half and move them to the bench.

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    1 - High/Low Range Gear

13. The high/low range gear may stay in the planetary gear during removal. Remove the high/low range gear.

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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.

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

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    1 - Annulus Gear

    2 - Planetary Gear Assembly

    3 - Snap Ring

16. Remove the planetary gear assembly from the annulus gear in the front case half.
17. If the annulus gear is damaged and requires replacement, remove the snap ring and annulus gear from the case half.

DISASSEMBLY OF THE PLANETARY ASSEMBLY 

1. Remove the snap ring.

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   1 - Lock Plate

2. Remove the carrier lock plate.

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   1 - Upper Thrust Washer

3. Remove the upper thrust washer.

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   1 - Input Gear

4. Remove the input gear.

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   1 - Lower Thrust Washer

5. Remove the lower thrust washer.

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DISASSEMBLY OF THE SHIFT SHAFT ASSEMBLY 

1. Separate the shift shaft assembly from the mainshaft assembly on the bench.
2. Remove the high/low shift fork from the shift shaft.

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   1 - Spacer

3. Remove the spacer.

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   1 - Shift Cam

4. Remove the shift cam.

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DISASSEMBLY OF THE MAINSHAFT ASSEMBLY 

1. Remove the snap ring.

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   1 - Spacer

2. Remove the spacer.

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   1 - Locating Pin

3. Remove the locating pin from the mainshaft.

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   1 - Snap Ring

   2 - Clutch Drum/Drive Sprocket

4. Remove the clutch drum/drive sprocket from the mainshaft and clutch assembly.
5. Aside from the clutch drum/drive sprocket, the mainshaft/clutch assembly is not serviceable. If the clutch, actuator levers or mainshaft are damaged, the transfer case assembly must be replaced.

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