Overhaul (Disassembly and Assembly)

Transfer Case Disassembly and Assembly









Special Tool(s)





Material

Disassembly








1. CAUTION: Discard all seals after removing them.

Remove the transfer case from the vehicle.





2. WARNING: Make sure the holding fixture lock pin is secure.

Using the special tool, secure the transfer case to a bench.
3. Remove the 4 damper bolts, then remove the damper.





4. If not previously done, remove the drain plug and drain the fluid.
Install the drain plug when finished draining and tighten to 17 Nm (13 ft. lbs.).





5. Index-mark the output flange and the upper output shaft.





6. Using the special tool to hold the output flange, remove the nut.
7. Remove the output shaft yoke washer.
8. Remove the output flange.
9. Remove and discard the output flange oil seal.
10. Remove the 17 transfer case cover bolts.





11. Separate the transfer case halves at the transfer case pry bosses.





12. Expand the snap ring, then remove the upper output shaft and ring gear.





13. Using the special tool, remove the upper output shaft support bearing.





14. Using the special tools, remove and discard the yoke-to-flange seal.





15. Remove the snap ring, then separate the upper output shaft from the ring gear.





16. Using a screwdriver, carefully remove the oil scoop.





17. Remove the snap ring retaining the bearing on the upper output shaft.





18. Using the special tools, remove the bearing.





19. Remove the 4 Torx(R) head screws, then remove the 2 damper snubbers.





20. Remove the output shaft thrust washer.





21. Remove the front planetary gear assembly.





22. Remove the thrust washer.





23. Remove the overdrive sun gear, the upper drive sprocket, the drive chain and the lower drive sprocket as an assembly.





24. Remove the thrust washer.





25. Remove the clutch assembly.





26. Remove the input shaft.





27. Using the special tools, remove the input shaft bearing.





28. While holding the front output shaft, remove the snap ring.





29. Remove the front output shaft.
30. Remove the front output shaft dust deflector.





31. Using the special tools, remove the front output shaft front bearing.





32. Using the special tools, remove and discard the front output shaft yoke-to-flange seal.
33. Remove and discard the input shaft seal.
34. Remove the front output shaft rear bearing.

Assembly

1. Install the front output shaft rear bearing.
2. Install a new input shaft seal.





3. Using the special tool, Install a new front output shaft yoke-to-flange seal.





4. Using the special tools, install the front output shaft bearing.
5. Install the front output shaft dust deflector.





6. Position the front output shaft.





7. While holding the front output shaft, install the snap ring.





8. Using the special tool, install a new input shaft bearing.





9. Install the input shaft.





10. Install the clutch assembly.





11. Install the thrust washer.





12. Assemble the overdrive sun gear, the upper drive sprocket, lower drive sprocket and the drive chain.
Align the blind spline on the lower drive sprocket with the narrow spline on the overdrive sun gear.





13. Install the overdrive sun gear, the upper and lower drive sprockets and the drive chain.





14. Install the thrust washer.





15. Install the front planetary gear assembly.





16. Install the output shaft thrust washer.





17. Position the 2 damper snubbers, then install the 4 Torx(R) head screws.
^ Tighten to 7 Nm (62 inch lbs.).





18. Assemble the upper output shaft and the ring gear.
1. Install the output shaft.
2. Install the snap ring.
3. Press on the bearing.





19. Install the snap ring.





20. Install the oil scoop.





21. Install the output shaft support bearing.





22. Install the upper output shaft and ring gear in the rear case half.
^ Expand the snap ring. Install the upper output shaft and the ring gear.
^ Release the snap ring.





23. Using the special tool, install the yoke-to-flange seal.





24. CAUTION: Applying excess silicone rubber can damage the internal components.
Apply a 3 -mm (0.11 -inch) bead of silicone rubber on the rear case mating surface.





25. Assemble the front and rear case halves.
26. Install the 17 transfer case bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
27. Install a new output flange oil seal.

28. NOTE: Align the index marks made during disassembly.

Install the output flange.

29. Install the output shaft yoke washer.





30. Using the special tool to hold the output flange, install the nut.
^ Tighten to 355 Nm (262 ft. lbs.).
31. Position the damper and install the 4 bolts.
^ Tighten to 22 Nm (16 ft. lbs.).
32. Install the transfer case into the vehicle.
33. Fill the transfer case.