Special Tools
• | J-2619-A Slide Hammer w/Adapter
|
• | J 3289-20 Holding Fixture
|
• | J 22912-B Rear Pinion and Axle Bearing Remover
|
• | J 26941 Bushing and Bearing Remover - 3-4 inch
|
• | J 36825 Output Shaft Oil Seal Remover - 4WD Models Only
|
• | J 45380 Transfer Case Rear Bushing Remover and Installer
|
• | J 45759 Assembly Fixture
|
• | J 45849 Bearing Remover
|
For equivalent regional tools, refer to
Special Tools.
- Mount the
J 3289-20 holding fixture
to a sturdy workbench.
- Attach the
J 45759 assembly fixture
on the transfer case using the adapter studs. All of the transfer case disassembly procedures can be performed with the case mounted to
the
J 45759 assembly fixture
.
- Install the
J 45759 assembly fixture
(2) into
J 3289-20 holding fixture
(1) and secure with pivot pin.
- Remove the drain plug. Ensure all of the transfer case fluid is drained out of the transfer case.
Caution: Refer to Transfer Case Seal Removal Caution in the Preface section.
Note: The front output shaft seal is a 2 piece internal seal. The inner seal race is a force fit on the front output shaft.
- Remove the front input shaft seal by inserting a flat-tipped screwdriver behind the inner race of the seal.
- Pry the inner seal race forward.
- Using a small pry bar, move the inner
seal race forward on the front input shaft.
- Remove the inner seal race from the front input shaft.
- Insert a flat-tipped screwdriver or a small pry bar between the lip of
the outer lip of the front output shaft seal and the transfer case.
- Remove the remaining part of the front output shaft seal from the transfer case.
- Remove the vehicle speed sensor (VSS) with O-ring seal.
Caution: Refer to Transfer Case Seal Removal Caution in the Preface section.
- Remove the rear output shaft seal by prying out with a flat-blade screwdriver.
- Using the
J 45380 bushing remover/installer
, remove the rear output shaft bushing.
- Remove the transfer case retaining bolts and the washers.
- Mark the location of the brackets.
Caution: Refer to Machined Surface Damage Caution in the Preface section.
- Using the
J 45358 case spreader
between the tabs on the case halves, shear the sealer holding the case halves together.
- Using pry bars at each side of the case, remove the case from the locating pins.
- Remove the rear case half from the front case half.
The rear output shaft will come out with the rear case half.
- Remove the planetary carrier assembly thrust washer.
- Remove the planetary carrier assembly.
- Remove the sun gear thrust washer.
- Remove the front input shaft.
- If the cup plug in the front output shaft is leaking,
remove the plug using a brass drift.
Note: If the chain and sprockets are to be used again, mark the relationship of the chain to the sprockets in order to mark the wear patterns.
- Remove the chain with the driven sprocket.
- Remove the sun gear with the drive
gear and viscous coupling. Lift up on the sun gear assembly while tapping down on the input shaft with a soft-face hammer.
- Using a hydraulic press and
J 22912-B pinion/bearing remover
, remove the bearing from the sun gear.
- Remove the drive gear from the sun gear.
- Remove the viscous coupling from the sun gear.
- Remove the input shaft from the front case.
- Using the
J-2619-A slide hammer
(1)
and the
J 36825 seal remover - 4WD
(2), remove the input seal.
30.1. | Poke a hole in the seal using a very sharp punch. |
30.2. | Thread the
J 36825 seal remover - 4WD
(2) into the hole. |
- Remove the input shaft bushing from the front case using
a hammer and brass drift.
- Using a brass drift, remove the front
output shaft bearing from the front case half.
- If necessary, remove the vent from the front case half.
- Remove the rear output shaft from the rear case half.
34.1. | Spread the rear output shaft rear bearing outer retaining ring (1). |
34.2. | Using a soft-face hammer, tap on the end of the rear output shaft. |
- Remove the annulus gear retaining ring.
- Remove the rear output shaft from the annulus gear.
- Inspect the bearing in the rear output shaft. Refer to
Transfer Case Cleaning and Inspection.
- If the bearing is faulty, remove the bearing using the
J 45849 bearing remover
.
• | Install the finger part of the
J 45849 bearing remover
in the bearing. |
• | Thread the driver part into the fingers. |
• | Remove the bearing from the fingers by squeezing the fingers together. |
- Remove the retaining ring for the rear
output shaft bearing and the speed reluctor wheel.
- Using a hydraulic press and the
J 22912-B pinion/bearing remover
, remove the speed reluctor wheel and the rear output shaft bearing
Do not use the speed reluctor wheel again.
- Remove the rear bearing for the front
output shaft from the rear case, using the
J 26941 bushing/bearing remover
(1) and the
J-2619-A slide hammer
(2).