Tools Required

1. Mount the J 3289-20 to a sturdy workbench.
2. Attach the J 45759 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 .



3. Install the J 45759  (2) into J 3289-20  (1) and secure with pivot pin.



4. Remove the drain plug. Ensure all of the transfer case fluid is drained out of the transfer case.

Notice: Refer to Transfer Case Seal Removal Notice in the Preface section.





Important: The front output shaft seal is a 2 piece internal seal. The inner seal race is a force fit on the front output shaft.

5. Remove the front input shaft seal by inserting a flat-tipped screwdriver behind the inner race of the seal.
6. Pry the inner seal race forward.



7. Using a small pry bar, move the inner seal race forward on the front input shaft.
8. Remove the inner seal race from the front input shaft.



9. 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.
10. Remove the remaining part of the front output shaft seal from the transfer case.



11. Remove the vehicle speed sensor (VSS) with O-ring seal.

Notice: Refer to Transfer Case Seal Removal Notice in the Preface section.




12. Remove the rear output shaft seal by prying out with a flat-blade screwdriver.



13. Remove the transfer case retaining bolts and the washers.
14. Mark the location of the brackets.

Notice: Refer to Machined Surface Damage Notice in the Preface section.




15. Using the J 45358 between the tabs on the case halves, shear the sealer holding the case halves together.
16. Using pry bars at each side of the case, remove the case from the locating pins.



17. Remove the rear case half from the front case half. The rear output shaft will come out with the rear case half.



18. Remove the planetary carrier assembly thrust washer.



19. Remove the planetary carrier assembly.



20. Remove the sun gear thrust washer.



21. Remove the front input shaft.



22. If the cup plug in the front output shaft is leaking, remove the plug using a brass drift.




Important: 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.

23. Remove the chain with the driven sprocket.



24. 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.



25. Using a hydraulic press and J 22912-B , remove the bearing from the sun gear.



26. Remove the drive gear from the sun gear.



27. Remove the viscous coupling from the sun gear.



28. Remove the input shaft from the front case.



29. Using the J 23907  (1) and the J 36825  (2), remove the input seal.

29.1.

Poke a hole in the seal using a very sharp punch.

29.2.

Thread the J 36825  (2) into the hole.




30. Remove the input shaft bushing from the front case using a hammer and brass drift.



31. Using a brass drift, remove the front output shaft bearing from the front case half.



32. If necessary, remove the vent from the front case half.




Important: Depending on the build date of the transfer case, it may have a rear output shaft bearing with or without a retaining ring groove. In early build transfer cases, the retaining ring (1) for the rear output shaft bearing was in front of the bearing (2). In later build transfer cases, the retaining ring (3) was moved rearward 5 mm (0.197 in) in the case. The bearings (4) have a groove and the retaining ring is installed in the groove.

33. Remove the rear output shaft from the rear case half.

33.1.

Spread the rear output shaft rear bearing outer retaining ring.

33.2.

Using a soft-face hammer, tap on the end of the rear output shaft.




34. Remove the annulus gear retaining ring.



35. Remove the rear output shaft from the annulus gear.



36. Inspect the bearing in the rear output shaft. Refer to Transfer Case Cleaning and Inspection .
37. If the bearing is faulty, remove the bearing using the J 45849 .

•	Install the finger part of the J 45849 in the bearing.

•	Thread the driver part into the fingers.

•	Remove the bearing from the fingers by squeezing the fingers together.




38. Remove the retaining ring for the rear output shaft bearing and the speed reluctor wheel.



39. Using a hydraulic press and the J 22912-B , remove the speed reluctor wheel and the rear output shaft bearing

Do not use the speed reluctor wheel again.




40. Remove the rear bearing for the front output shaft from the rear case, using the J 26941  (1) and the J 23907  (2).