Disassembly
DISASSEMBLY PROCEDURE^ Tools Required
- J 22912-01 Bearing Remover
- J 23907 Puller
- J 2619-01 Slide Hammer
- J 29369-01 Output Shaft Bearing Remover
- J 38427 Output Shaft Needle Bearing Remover
1. Use solvent and a stiff brush in order to clean the transfer case.
2. Remove the front output flange nut.
3. Remove the washer.
4. Remove the rubber sealing washer.
5. Remove the output flange.
6. Remove the vehicle speed sensor bolt.
7. Remove the vehicle speed sensor.
8. Remove the front cover to rear case bolts.
9. Use screwdrivers in order to remove the front cover. Pry only on the tabs.
IMPORTANT: : Do not damage the sealing surfaces when prying apart the transfer case.
10. Remove the front output shaft spacer.
11. Remove the output shaft and drive sprocket.
12. Remove the drive chain.
13. Remove the magnet.
14. Remove the input shaft.
15. Remove the sun gear shaft assembly.
16. Remove the thrust washer and sun gear.
17. Remove the planet carrier assembly. The planet carrier assembly includes the thrust washer.
18. Remove the extension housing bolts.
19. Remove the breather assembly.
20. Remove the extension housing.
20.1. Rotate the transfer case half way.
20.2. Support the output shaft assembly from the inside.
21. Remove the snap ring from the output bearing.
22. Remove the input shaft bearing, the output shaft, and the ring gear as one assembly.
23. Remove the snap ring.
24. Remove the output shaft assembly.
25. Remove the output shaft oil seal.
26. Remove the input shaft oil seal.
27. Remove the snap ring.
28. Use the J 2619-01 and the J 29369-01 in order to remove the output shaft bearing.
29. Remove the output shaft oil seal.
30. Use the J 22912-01 in order to remove the sun gear shaft bearing.
31. Remove the drive sprocket spacer.
32. Remove the drive sprocket.
33. Remove the viscous clutch.
34. Use the J 23907 in order to remove the input shaft pilot bearing.
35. Use the J 23907 and J 38427 in order to remove the output shaft rear bearing.