Disassembly
DISASSEMBLY
EXTERNAL ELECTRIC SHIFT
1. Remove bolt (1).
2. Remove three bolts (3).
3. Remove sensor and harness bracket.
4. Remove speed sensor assembly.
5. Remove motor assembly.
COVER ASSEMBLY
1. Remove nine bolts (1). This will free wiring harness clip and identification tag. Use care not to lose identification tag.
It contains information required for ordering replacement parts.
2. Pry at the bosses provided on the cover and transfer case to break the sealant bond loose. Then, lift cover assembly straight up to remove.
3. On electric shift units, remove oil seal (5), bearing, three nuts and clutch coil assembly.
4. Remove snap ring and pull ball bearing from cover. This will free speedo gear.
5. Pull needle bearing from cover.
6. Pull oil seal (15) from cover.
7. Remove magnet from slot in case.
8. Remove return spring from rail shaft.
9. Scrap and clean sealant from mating faces of cover and transfer case. Use care not to damage metal faces or allow scrapings to fall into transfer case.
LOCK SHIFT
1. From electric shift only, remove retaining ring and slide clutch housing from shift collar hub.
2. Remove shift collar hub from output shaft.
3. Together, slide 2W-4W lockup assembly and lockup fork from output shaft and rail shaft. Separate assemblies and remove rail shaft.
4. To disassemble 2W-4W lockup assembly, remove snap ring, lockup hub and return spring from lockup collar.
5. One-piece, plastic lockup fork replaces earlier fork assembly with metal fork and separate roller parts.
CHAIN DRIVE
1. Remove snap ring and spacer from output shaft (front).
2. Together, slide drive sprocket, driver sprocket and drive chain from output shafts (rear and front). Separate sprockets and chain when out of assembly.
REDUCTION SHIFT
1. Remove reduction hub and reduction shift fork assembly from transfer case.
2. Remove two facings from shift fork assembly.
3. Disassemble fork assembly only if parts replacement is required.
Cut plastic retainer to remove, freeing pin and cam roller.
FRONT OUTPUT SHAFT
1. Hold yoke and remove nut and washer.
Pull yoke assembly and oil seal.
2. Press deflector from yoke only if replacement is required.
3. Remove output shaft.
ADAPTER, INPUT SHAFT AND GEAR CARRIER
1. Remove breather.
2. Remove six bolts (2).
Carefully pry front adapter up to break sealant band with transfer case. Use care not to damage adapter or case.
3. Remove adapter assembly, input shaft assembly and gear carrier assembly as an assembled group.
4. Holding end of input shaft on workbench press down on adapter while expanding long ends of snap ring.
5. Remove snap ring and pump oil seal from front adapter.
Remove pin only if replacement is required.
6. Remove retaining ring (8). Pull bearing and thrust washer from end of input shaft assembly. Remove input shaft assembly from gear carrier assembly.
7. To disassemble input shaft assembly, pull sleeve bearing and needle bearing from input shaft.
8. Remove retaining ring (16), thrust plate end sun gear from planet carrier assembly.
SHIFT CAM (Electric parts)
1. Remove electric shift cam group (1 through 4) from transfer case as an assembly.
2. Slide electric shift cam off shift shaft.
3. Clamp retainer end of shift shaft.
Keeping fingers away from spring ends, pry torsion spring out of engagement with shaft drive tang using a screwdriver.
4. Remove torsion spring and spacer from shift shaft.
CASE ASSEMBLY
1. Pull oil seal.
2. Remove retaining ring and pull ball bearing.
3. Remove dowel pins from transfer case only if they are loose or damaged.
4. Press ring gear out of transfer case only if ring gear must be replaced.
DISASSEMBLY
1. Remove the transfer case from the vehicle.
2. Remove the flange washer and nut.
3. Disconnect the shift motor/clutch coil connector and the speed sensor connector.
4. Remove the outer tube of the speed sensor connector wire.
5. Remove the wire fixing cap in the rear of the speed sensor connector.
6. Disconnect the speed sensor connector.
7. Remove the shift motor.
8. If necessary, remove the front and rear speed sensor.
9. Remove the mounting bolts for the rear and front case.
10. Make sure that the front case is facing downward so that the rear cover is facing upwards.
11. Separate the front case from the rear case.
12. Remove all traces of gasket sealant from the mating surfaces of the front case and rear case.
13. If the speedometer drive gear is to be replaced, first remove the flange seal or use the Impact Slide Hammer to pop off the flange seal.
CAUTION:
Do not damage the bearing and the bearing case.
14. Remove the speedometer drive gear and upper tone wheel.
15. If the rear output shaft bearing requires replacing, remove the internal snap ring that retains the bearing in the bore.
16. From the outside of the case, drive out the bearing.
17. Remove the three nuts and washers retaining the clutch coil assembly to the rear case.
18. Pull the coil assembly, along with the O-rings and wire, from the case.
19. Remove the bearing assembly from the output shaft.
20. Remove the clutch housing from the output shaft.
21. Remove the balls and the apply cam and the waver washer from the output shaft.
22. Remove the snap ring from the output shaft.
23. Remove the clutch pack and lower tone wheel from output shaft.
24. Remove the chain, the driven sprocket and the drive sprocket as an assembly.
25. Remove the thrust washer from the output shaft.
26. Remove the oil pan magnet from the slot in the front of the case bottom.
27. Remove the output shaft and oil pump as an assembly.
28. If required, to remove the pump from the output shaft, rotate the pump to align.
29. Pull out the shift rail.
30. Remove the helical cam from the front case.
31. If required, remove the helical cam, torsion spring and sleeve from the shaft.
32. Remove the high-low range shift fork and collar as an assembly.
33. Expand the tangs of the large snap ring in the case using the Ring Plier or equivalent.
34. With the input shaft against a bench, push the case down and slide the main drive gear bearing retainer off the bearing.
35. Lift the input shaft and front planet from the case.
36. If required, remove the oil seal from the case by prying and pulling on the curved-up lip of the oil seal or use the Slide Hammer to pop off the oil seal.
37. Remove the internal snap ring from the planetary carrier.
38. Separate the front planet from the input shaft.
39. Remove the external snap ring from the input shaft.
40. Place the input shaft in a vise and remove the bearing.
41. Remove the thrust, thrust plate and the sun gear off the put shaft.
42. Inspect the bushing and needle bearing in the end of the input shaft for wear or damage.
CAUTION:
Under normal use, the needle bearing and bushing should not require replacement.
If replacement is required, the bushing and needle bearing must be replaced as a set.
43. If required, remove the front yoke to flange seal by prying and pulling on the curved-up lip of the yoke to flange seal.
44. If required, remove the internal snap ring retaining the front output shaft ball bearing and remove the bearing.