Disassembly

Special Tools:

Disassembly

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1. Remove the transfer case from the vehicle.

2. Note: The rear output shaft nut has a self-locking feature and must be replaced once it is removed.

Remove and discard the rear output shaft nut.

3. Remove the output shaft yoke washer and the rear output flange.

4. Use the Slide Hammer and the Seal Remover to remove the yoke to flange seal.

5. Remove the spacer.
6. Remove the transfer case shift motor.

7. Remove the front bolts that retain the rear case to the front case.

8. Remove the rear bolts that retain the front case to the rear case.

9. Note: Make sure that the front case is facing downward so that the rear cover is facing upwards.

Insert a breaker bar between the pry bosses, and separate the front case from the rear case.
10. Remove all traces of RTV sealant from both cases.

11. With the rear case on the workbench, remove the snap ring that retains the output shaft bearing.

12. From the outside of the case, drive out the rear output shaft bearing using the Driver Handle and the Bearing Puller.

13. Using the Impact Slide Hammer and Puller Collet, remove the front output shaft needle bearing.

14. Remove the nyloc nuts retaining the clutch coil assembly to the rear case, and pull the assembly along with the O-rings and brown wire from the case.

15. Remove the lockup return spring from the boss on the fork.

16. Remove the clutch housing from the output shaft.

17. Remove the 2W-4W lockup and the 2W-4W shift fork as an assembly.

18. Pull out the shift shaft rail.

19. Remove the internal snap ring.

20. Pull the lockup hub and sleeve return spring from the lockup collar.

21. Remove the helical cam from the front case.

22. Remove the external snap ring and thrust washer that retains the driven sprocket to the front output shaft.

23. Remove the chain, driven sprocket and drive sprocket as an assembly.

24. Remove the oil pan magnet from the slot in the front of the case bottom.

25. CAUTION: If there is removal resistance, do not pound or use force to disassemble the pump; start over again.

Remove the output shaft and oil pump as an assembly.

26. If required, rotate the pump to align the cover keyway to the pin of the output shaft, and pull the pump straight out.

27. Measure and record the oil pump drive pin height above the diameter of the output shaft, and remove the drive pin from the output shaft.

28. Remove the snap ring retaining the front output shaft.

29. Remove the front output shaft.

30. Remove the high-low range shift fork and collar as an assembly.

31. Turn the front case over, and remove the six bolts retaining the main drive gear bearing retainer to the front case.

32. Remove the main drive gear bearing retainer, input shaft and front planet as an assembly.

33. Using snap ring pliers, expand the tangs of the large snap ring and remove the main drive gear assembly from the bearing.

34. Use the Impact Slide Hammer and Seal Remover to remove the input yoke to flange seal from the main drive gear bearing retainer.

35. Using snap ring pliers, remove the snap ring retaining the input shaft bearing from the input shaft.

36. Invert the main drive gear assembly, and pull the input shaft out of the bearing and planetary.

37. Remove the internal snap ring, the thrust washer, thrust plate and the sun gear from the main gear assembly.

38. Note: The bushing and needle bearing in the input shaft must be replaced as a set.

Using a suitable press, remove the bearing and bushing.
1 Position the input shaft on the Axle Bearing/Seal Plate, and use the Pinion Bearing Cone Replacer as a spacer.
2 Insert the Input Shaft Bearing Remover into the input shaft.
3 Tighten the actuator pin until it stops, and press the bearing and bushing out together.

39. Remove the ring gear from the front case half, using a press.

40. Remove the internal snap ring retaining the front output shaft ball bearing, and remove the bearing.

41. Remove the front yoke to flange seal, using the Impact Slide Hammer.