Transfer Case Disassemble (1)

Transfer Case Disassemble Single Use Fasteners and Components Transfer Case Access Hole Plug Transfer Case Four Wheel Drive Clutch Housing Retaining Ring Transfer Case Front Output Shaft Boot Transfer Case Front Output Shaft Boot Clamp [2x] Transfer Case Front Output Shaft Drive Sprocket Retaining Ring Transfer Case Front Output Shaft Seal Transfer Case Input Shaft Bearing Outer Retaining Ring Transfer Case Input Shaft Bearing Retaining Ring Transfer Case Input Shaft Seal Transfer Case Oil Pump Suction Pipe Seal Transfer Case Rear Output Shaft Rear Bearing Retaining Ring [2x] Transfer Case Rear Output Shaft Seal Transfer Case Two/Four Wheel Drive Actuator Position Sensor Gasket Transfer Case Two/Four Wheel Drive Clutch Retaining Ring Transfer Case Vent Special Tools DT-45759 Assembly Fixture DT-51204 Case Separating Tool GE-3289-20 Holding Fixture Equivalent regional tools: Special Tools Transfer Case Disassemble

Transfer Case Disassemble (1) — figure 1

1. Install DT-45759 Assembly Fixture  (5) to the transfer case nuts (3)
2. Mount the DT-45759 Assembly Fixture (5) and transfer case (4) to the GE-3289-20 Holding Fixture  (1).

Note

Always secure with the pivot pin after rotating. The transfer case can be rotated 360 degrees to facilitate repair.

Transfer Case Disassemble (1) — figure 2

3. Transfer Case Two/Four Wheel Drive Actuator Bolt/Screw (2) » Remove [4x]
4. Transfer Case Two/Four Wheel Drive Actuator (1) » Remove

Transfer Case Disassemble (1) — figure 3

5. Transfer Case Two/Four Wheel Drive Actuator Position Sensor Bolt (3) » Remove [2x]
6. Transfer Case Two/Four Wheel Drive Actuator Position Sensor (2) » Remove
7. Transfer Case Two/Four Wheel Drive Actuator Position Sensor Gasket (1) » Remove and DISCARD

Transfer Case Disassemble (1) — figure 4

Note

Remove the vent as required. If vent removal is required, install a NEW vent during assembly.

8. Transfer Case Vent (1) » Remove and DISCARD
9. Transfer Case Access Hole Plug (2) » Remove and DISCARD [2x]
10. Transfer Case Oil Fill Plug (3) » Remove
11. Transfer Case Oil Drain Plug (4) » Remove

Transfer Case Disassemble (1) — figure 5

Caution

Refer to Transfer Case Seal Removal Caution.

12. Transfer Case Rear Output Shaft Seal (1) » Remove and DISCARD

Transfer Case Disassemble (1) — figure 6

13. Transfer Case Half Bolt (1) » Remove [17x]
14. Transfer Case Bracket (2) » Remove
15. Transfer Case Rear Case Half (3) » Remove

Caution

Refer to Machined Surface Damage Caution. 15.1. Use opposing pry bars at casting bosses to spread the case. 15.2. Use snap ring pliers to release the transfer case rear output shaft outer retaining ring from the transfer case rear output shaft rear bearing assembly. 15.3. Split the case apart using the DT-51204 Case Separating Tool.

Transfer Case Disassemble (1) — figure 7

16. Transfer Case Two/Four Wheel Drive Actuator Shaft Gear (1) » Remove
17. Transfer Case Oil Pump Suction Pipe (2) » Remove
18. Transfer Case Oil Pump Suction Pipe Seal (3) » Remove

Transfer Case Disassemble (1) — figure 8

19. Transfer Case Rear Output Shaft Assembly (1) » Remove

Note

Mount the assembly into a soft-jaw vice or holding fixture for disassembly.

20. Remove the transfer case actuator shaft and cam assembly (2).
21. Remove the transfer case front output shaft drive chain assembly (3).

Transfer Case Disassemble (1) — figure 9

22. Transfer Case Rear Output Shaft Rear Bearing Retaining Ring (1) » Remove and DISCARD [2x]
23. Use an arbor press or suitable puller to remove the Transfer Case Rear Output Shaft Rear Bearing (2) from the rear output shaft.
24. Transfer Case Rear Output Shaft Bearing Spacer (3) » Remove

Transfer Case Disassemble (1) — figure 10

25. Transfer Case Oil Pump (1) » Remove
26. Transfer Case Front Output Shaft Drive Sprocket Retaining Ring (2) » Remove and DISCARD
27. Transfer Case Front Output Shaft Driven Sprocket Spacer - Rear (3) » Remove
28. Transfer Case Front Output Shaft Drive Sprocket (4) » Remove
29. Transfer Case Four Wheel Drive Clutch Housing Retaining Ring (5) » Remove and DISCARD

Transfer Case Disassemble (1) — figure 11

30. Transfer Case Four Wheel Drive Clutch Housing (1) » Remove
31. Transfer Case Front Output Shaft Driven Sprocket Spacer - Front (2) » Remove
32. Transfer Case Two/Four Wheel Drive Clutch Retaining Ring (3) » Remove and DISCARD
33. Transfer Case Four Wheel Drive Clutch Shim (4) » Remove

Transfer Case Disassemble (1) — figure 12

34. Transfer Case Four Wheel Drive Clutch Hub (1) » Remove
35. Transfer Case Four Wheel Drive Clutch Pressure Plate – Friction (2) » Remove [8x]
36. Transfer Case Four Wheel Drive Clutch Pressure Plate – Steel (3) » Remove [7x]

Transfer Case Disassemble (1) — figure 13

37. Transfer Case Four Wheel Drive Clutch Pressure Plate Spring (1) » Remove [4x]
38. Transfer Case Four Wheel Drive Clutch Pressure Plate – Apply (2) » Remove
39. Transfer Case Control Actuator Lever Washer (3) » Remove
40. Transfer Case Control Actuator Lever Bearing Assembly (4) » Remove

Transfer Case Disassemble (1) — figure 14

41. Transfer Case Scissor Mechanism Lever (1) » Remove
42. Transfer Case Scissor Lever Ball (2) » Remove [3x]
43. Transfer Case Scissor Mechanism Lever (3) » Remove
44. Transfer Case Control Actuator Lever Bearing Assembly (4) » Remove
45. Transfer Case Control Actuator Thrust Bearing (5) » Remove

Transfer Case Disassemble (1) — figure 15

Caution

Refer to Machined Surface Damage Caution.

46. Transfer Case Input Shaft Seal 46.1. Drill a pilot hole, as required, and insert a self-tapping screw into the body of the seal. 46.2. Use a plier or slide hammer type tool to remove the seal from the bore.

Transfer Case Disassemble (1) — figure 16

47. Transfer Case Input Shaft Seal (1) » Remove and DISCARD
48. Transfer Case Input Shaft Bearing Outer Retaining Ring (2) » Remove and DISCARD
49. Transfer Case Input Shaft (3) » Remove
50. Transfer Case Input Shaft Pilot Bearing (4) » Remove

Note

Only remove the bearing if faulty. Front Output Shaft and Input Shaft Cleaning and Inspection.

51. Transfer Case Input Shaft Bearing Retaining Ring (5) » Remove and DISCARD
52. Transfer Case Input Shaft Bearing (6) » Remove

Transfer Case Disassemble (1) — figure 17

53. Transfer Case Front Output Shaft Boot Clamp (1) » Remove and DISCARD [2x]
54. Transfer Case Front Output Shaft Boot (2) » Remove and DISCARD
55. Transfer Case Front Output Shaft Oil Slinger (3) » Remove

Note

Slinger will need to be pressed out during T-case disassembly process.

Transfer Case Disassemble (1) — figure 18

56. Transfer Case Front Output Shaft Seal (1) » Remove and DISCARD

Note

Seal can be driven out from inside the case half.

57. Transfer Case Front Output Shaft (2) » Remove

Note

Press the front output shaft assembly from the front case half using an arbor press or soft-face hammer.