1. Transfer Case Disassemble
Disassembly Procedure
1. Remove the speed sensor.
2. Remove the rear output bearing plug.
3. Separate the rear output retaining ring.
4. Remove the 17 bolts that hold front and rear case halves together.
5. Using the 2 slots provided for prying, separate the case halves.
6. Inspect the oil pump wear sleeve in the rear case for damage.
7. Remove the mode fork spring.
8. Remove the rear output bearing retaining ring.
9. Remove the rear output bearing. Note that the snap ring side faces into the rear of the case half.
10. Remove the tone wheel retaining ring.
11. Remove the tone wheel.
12. Remove the pump asm-gerotor and separate oil tube. Do not loosen O-ring.
13. Remove the oil tube and oil screen.
14. Remove the magnet.
15. Remove the rotor O-ring seal from the mainshaft.
16. Remove the sprocket retaining rings from the driven and drive sprockets.
17. Remove both sprockets and chain as an assembly.
18. Remove the mode fork assembly and mainshaft as an assembly.
19. Remove the mode fork and shift rail.
20. Separate shift rail from mode fork.
21. Remove syncro clutch gear. Note that the gear is installed collar side out and flat side in.
22. Remove the gear retaining ring from the syncro assembly.
23. Remove the syncro assembly.
24. Remove the outer ring.
25. Remove the middle ring.
26. Remove the inner cone.
27. Remove the synchronizer hub from the mainshaft.
28. Remove the poppet assembly. Note that there are 3 pieces to the poppet spring:
^ Poppet screw-O-ring
^ Poppet spring
^ Poppet plunger
29. Remove the range fork and range shift sleeve assembly.
30. Remove the sector shaft retaining ring.
31. Remove the sector shaft.
32. Remove the sector shaft front bearing retaining ring.
33. Remove the sector shaft front bearing.
34. Remove the sector shaft front bearing internal case retaining ring.
35. Remove the lever assembly and the sector bolt.
36. Remove the sector assembly.
37. Remove the front input oil seal.
38. Remove the input gear retaining ring from seal side.
39. Remove the input gear assembly and planetary assembly.
40. Remove the planetary gear from the input gear assembly retaining ring.
41. Separate input gear and planetary assembly.
42. Remove the lock plate carrier and 2 input gear/planetary housing thrust washers.
43. Remove the front input bearing retaining ring.
44. Remove the front input bearing.
45. Remove the front output seal.
46. Remove the vent assembly.
47. Remove the switch assembly.
48. Remove the sector shaft support assembly and stat-O-seal support assembly.