Special Tools
• | J 3289-20 Holding Fixture
|
• | J 26941 Bushing and Bearing Remover - 3-4 inch
|
• | J 45380 Transfer Case Rear Bushing Remover and Installer
|
• | J 45548 Mainshaft Support Bushing/Bearing Remover
|
• | J 45759 Assembly Fixture
|
For equivalent regional tools, refer to
Special Tools
- Attach the
J 45759 assembly
fixture
to 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
.
- Mount the
J 3289-20 holding fixture
(1) to a sturdy workbench.
- Install the
J 45759 assembly fixture
(2) into
J 3289-20 holding fixture
(1)
and secure with pivot pin.
- Remove the drain plug and the fill 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 two piece internal seal. The inner seal race is a force fit on the front output shaft.
- Remove the front output shaft seal by inserting a flat-tip 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 output shaft.
- Remove the inner seal race from the front output shaft.
- Insert a flat-tip screwdriver or a small pry bar between 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.
Caution: Refer to Transfer Case Seal Removal Caution in the Preface section.
- Remove the rear output shaft seal by prying it out with a flat-blade screwdriver.
- Remove the transfer case retaining
bolts and washers.
Mark the location of the brackets.
Caution: Refer to Transfer Case Seal Removal Caution in the Preface section.
- Using the
J 45358 case spreader
between the tabs on the case halves, shear the sealer that is 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 with the rear case half.
- Remove the rear sun gear.
- Remove the sun gear thrust washer.
- Remove the planetary differential assembly.
- Remove the front sun gear.
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 drive sprocket and driven sprocket.
- Remove the input shaft.
- Remove the front output shaft assembly.
- If the cup plug in the front output shaft is leaking,
remove the plug using a brass drift.
- Using a hammer and a suitable punch, remove the input seal.
- Using the
J 26941 bushing and bearing remover
(3), the
J 45124 puller bridge
(1), and the
J-45124-9 puller legs
(2), remove the input shaft bearing for the front input shaft from the front case.
- 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.
- Using
J 45380 bushing remover
and installer
, remove the rear output shaft bushing.
- Remove the rear output shaft from the
rear case half.
29.1. | Spread the rear output shaft rear bearing outer retaining ring. |
29.2. | Using a soft-face hammer, tap on the end of the rear output shaft. |
- Remove the retaining ring for the rear
output shaft bearing.
- Using a hydraulic press, remove the rear output shaft bearing.
- Inspect the mainshaft rear support
bushing in the rear output shaft for being faulty. Refer to
Transfer Case Cleaning and Inspection.
- Using the
J 2619-01 slide hammer
(1) and the
J 45548 bushing/bearing remover
(2),
remove the mainshaft rear support bushing from the rear output shaft.
- Using the
J 26941 bushing and bearing remover
(3), the
J 45124 puller bridge
(1), and the
J-45124-9 puller legs
(2), remove the rear bearing for the front output shaft from the rear case.