Disassembly

Fig. 9 Exploded View:

Refer to Fig. 9, when performing disassembly and assembly procedures.

1. Drain fluid, then install and torque drain plug to 10-20 ft. lbs.
2. Remove electrical connectors from two sensors on rear case half, then the connector for electric clutch assembly. Push in the tabs of the connector to separate the connector from the socket. Pull wiring harness from the clips on the transfer case. Do not pull on wires of connector. Push in the locking tabs to separate the connectors from the sockets.
3. Remove self-tapping screws that fasten sensors to rear case half, then the sensors.
4. If damaged, remove breather tube from front case half.

Fig. 10 Output Shaft Lockmut Removal:

5. Remove locknut from front output shaft using front output shaft nut wrench tool No. T90T-7127-E and front output shaft holding tool No. T90T-7127-F or equivalents. Hold nut with the holding tool and turn splines of the front output shaft with wrench to remove the locknut from the shaft, Fig. 10.
6. Remove deflector, then the steel bushing from front output shaft.
7. Remove oil seal for front output shaft from front case half using seal remover tool No. 1175-AC and slide hammer tool No. T50T-100-A or equivalents.
8. Remove O-ring from front output shaft.
9. Remove snap ring that fastens bearing on front output shaft, in the nose of the front case half.
10. Mark position of clips for wiring harness on the transfer case. The clips must be installed in original position during assembly.
11. Remove round head drive screws that fasten case halves together, then the clips for the wiring harness and any tags.
12. Separate the case halves using suitable tool and case pry bosses.
13. Remove all gasket material from case halves. Do not damage the mounting surfaces on the case halves.
14. Tap on end of front output shaft assembly to separate shaft from case, then remove front output shaft assembly and drive chain. If necessary, disassemble the front output shaft.
15. Use an appropriate driver to remove the roller bearing from the front case half, then remove input shaft oil seal from front case half using seal remover tool No. 1175-AC and slide hammer tool No. T50T-100-A or equivalents.
16. Remove electric clutch and planetary gear assembly from rear case half. Ensure the wire for electric clutch is removed from the slot in the case.
17. Remove thrust washer from bottom of ring gear in the rear case half, then turn case over so inside of case is toward the bench, bump the rear case half against the bench so the ring gear falls out of the case.

Fig. 11 Rear Output Shaft Oil Seal Removal:

18. Remove rear output shaft oil seal from rear case half using seal remover tool No. T74P-77248-A and slide hammer tool No. T50T-100-A or equivalents, Fig. 11.
19. Use snap ring pliers, remove snap ring that fastens rear output assembly inside the rear case half.
20. Remove output shaft assembly from rear case half by tapping on the end of shaft with a plastic hammer. If necessary, disassemble the rear output shaft.
21. Using collet puller tool No. T87P-7120-D and slide hammer T50T-100-A, remove front output shaft needle bearing assembly from the rear case half. The needle bearing assembly supports the rear of the front output shaft in the rear case half.
22. If damaged, remove oil baffles from front case half.