Tools Required
• | J 23907
Slide Hammer with Bearing Adapter |
• | J 26941
Bushing and Bearing Remover (3-4 inch) |
• | J 36513
Gear and Bearing Separator Plate |
• | J 44737
Shift Rail Bearing Remover |
• | J 45380
Transfer Case Rear Bushing Remover and Installer |
Important: Because of manufacturing design changes made during this model year, the transfer case was manufactured with either a 1st design clutch lever, clutch pressure plate bearing, and clutch inner plate or a 2nd design
clutch lever, clutch pressure plate bearing, and clutch inner plate. The 2nd design components are larger for improved durability. These components can be identified by the following:
• | The 1st design clutch lever has the anti-spin boss (1) located at the bottom, the pivot pads (2) are narrow, the part number is 29820 (3). |
• | The 2nd design clutch lever is relieved (4) for the larger clutch inner plate, the pivot pads (5) are wider going from edge to edge, the anti-spin boss (6) is located at the top, the part number is 53308 (7). |
• | The 1st design clutch pressure plate bearing outer diameter measures 82 mm (3.228 in) (a). |
• | The 1st design clutch inner plate outer diameter measures 76.25 mm (3.002 in) (b). |
• | The 2nd design clutch pressure plate bearing outer diameter measures 93 mm (3.661 in) (c). |
• | The 2nd design clutch inner plate outer diameter measures 87.75 mm (3.455 in) (d). |
Do not interchange 1st design components with 2nd design components.
- If available, using the adapter studs, attach the
J 45759
(2) to the transfer case.
- Mount the
J 3289-20
(1) to a sturdy workbench.
- Install the
J 45759
(2) into the
J 3289-20
(1) and secure with the pivot pin.
- Remove the drain plug.
- Tip the transfer case to remove any remaining transfer case fluid.
Notice: Refer to Transfer Case Seal Removal Notice in the Preface section.
- Using a fine flat-bladed screwdriver and a mallet, loosen the front input shaft seal.
- Using a small block of wood and a large flat-bladed screwdriver, remove the front input shaft seal
from the transfer case.
- Remove the front input shaft seal.
- Remove the dust seal from the front output shaft. The
front output shaft oil seal does not require removal at this time.
- Remove the transfer case bolt that is retaining the wiring harness bracket.
- Mark the location of the wiring harness bracket bolt.
- Remove the encoder/motor mounting bolts.
- Remove the encoder/motor assembly.
- Remove both vehicle speed sensors (VSS) and O-ring seals from the rear
extension.
Notice: Refer to Transfer Case Seal Removal Notice in the Preface section.
- Remove the rear output seal.
- Inspect the rear output shaft bushing for scoring or wear.
- Remove the rear output shaft bushing using the
J 45380
.
• | Install the finger section of the
J 45380
in front of the bushing. |
• | Install the tube and forcing screw assembly to the finger section. Ensure the forcing screw is backed out. |
• | Using a wrench on the forcing screw, remove the rear output shaft bushing. |
Important: Remove the rear extension and case half bolts at the same time for easier rear case disassembly.
- Remove the rear extension mounting bolts.
- Remove the case half bolts.
Notice: Refer to Machined Surface Damage Notice in the Preface section.
- Install the
J 45358
between the tabs on 1 side of the case.
Important:
• | Ensure that all of the case half bolts have been removed. |
• | DO NOT use screwdrivers or pry bars to separate the transfer case halves. The special tool must be used to separate the transfer case halves properly. |
- Using the
J 45358
, shear the sealer securing the front and rear case half together.
- Move the
J 45358
to the tabs on the other side of the case and shear the sealer.
- Use a suitable prying tool at 1 side of the case half.
- Use a suitable prying tool at the other side of the cased halves.
- Working both tools, separate the front output shaft from the front output shaft bearing, and the input shaft from the output shaft.
- Remove the front case half from the
rear case half. Only the input gear assembly will remain with the front case half.
Important: If using the drive chain and sprockets again, mark the position of the drive chain to the sprockets in order for the proper wear pattern alignment.
- Remove the front output shaft from the front output shaft rear bearing.
- Remove the drive chain assembly from the drive gear on the output shaft and the driven gear on the front output shaft.
- Remove the retaining ring for the high/low shift fork.
- Remove the top shift fork spring.
- Remove the shift fork assembly from the shift fork shaft.
- Separate the shift fork from the range sleeve.
- Remove the bottom shift fork spring.
- Insert a screwdriver in the slot of the rear extension.
- Remove the rear extension from the rear case half.
- Using the
J 44707
(1), the
J 44759
(2), and the
J 36513
(3), remove the speed sensor reluctor wheel from the rear output shaft.
- Discard the speed sensor reluctor wheel after removal.
- Remove the rear output shaft assembly.
- Remove the clutch lever from the rear case half.
- Remove the shift fork shaft with the shift detent lever. Rotate the control actuator lever shaft in order
to remove the shift detent lever.
- Remove the oil pump cover mounting bolts.
- Remove the oil pump cover.
- Remove the oil pump drive gear, the inner rotor.
- Remove the oil pump driven gear, the outer rotor.
- While pushing down on the clutch apply plate, remove the clutch pressure plate bearing retaining ring.
- Remove the clutch inner plate.
- Remove the clutch pressure plate bearing.
- Remove the clutch apply plate.
- Remove the clutch spring.
- Remove the clutch hub retaining ring.
- Remove the clutch housing assembly.
- Hold on to the clutch plates, and turn the clutch housing over on a workbench.
- Remove the clutch housing from the clutch plates and the clutch hub.
- Remove the clutch hub from the clutch plates.
- Remove the drive sprocket retaining ring from the clutch
housing.
- Remove the drive sprocket from the clutch housing.
- Remove the clutch housing retaining ring from the rear output shaft.
- Remove the rear output shaft rear thrust washer.
- Using a press, remove the planetary gear assembly.
59.1. | Support the front case half on press plates, to allow the planetary gear assembly removal. |
59.2. | Use a suitable adapter to press on the input gear bearing. |
- Using a press, remove the input gear bearing.
60.1. | Support the planetary gear assembly on press plates, to allow removal of the input gear. |
60.2. | Use a suitable adapter to press on the input gear. |
- Remove the input gear.
- Remove the planetary gear large diameter thrust washer.
- Remove the input gear smaller diameter thrust washer.
- If necessary, remove the bore seal
and the input gear thrust bearing from the input gear.
- Remove the driven gear retaining ring from the front
output shaft.
- Remove the driven gear from the front output shaft.
- Using a hydraulic press and a suitable adapter on the
front input shaft, remove the front speed sensor reluctor wheel.
Important: The vent only requires removal if it is damaged.
- Remove the vent.
- Remove the front output shaft VSS and O-ring
seal from the rear case.
- Remove the chip collector magnet from the rear case.
- Remove the oil pump suction pipe with the oil pump screen.
- Remove the retaining ring for the control
actuator lever shaft.
- Discard the retaining ring.
- Remove the control actuator lever shaft from the rear
case.
Important: Only remove the bearings if they are faulty. Do not use the bearings again.
- Inspect the front output shaft rear bearing for being faulty. Refer to
Transfer Case Cleaning and Inspection.
- Using the
J 23907
(1) and the
J 26941
(2), remove the rear bearing for the front output shaft.
Important: Only remove the bearings if they are faulty. Do not use the bearings again.
- Inspect the rear output shaft bearing for being faulty. Refer to
Transfer Case Cleaning and Inspection.
Important: The bushing surface for the oil pump is located by the output shaft bearing. When using the
J 26941
, the jaws must not come in contact with the oil pump bushing surface.
- Using the
J 23907
(1) and the
J 26941
(2), remove the rear output shaft bearing from the rear case. Ensure the jaws on the
J 26941
are between the bearing and the oil pump bushing.
Important: Only remove the bearings if they are faulty. Do not use the bearings again.
- Inspect the control actuator lever shaft bearing for being faulty. Refer to
Transfer Case Cleaning and Inspection.
- Using the
J 44707
(2) and the
J 44737
(1), remove the control actuator lever shaft bearing.
Notice: Refer to Transfer Case Seal Removal Notice in the Preface section.
- Using a suitable prying tool, remove the front output shaft seal.
- Discard the seal.
Important: Only remove the bearings if they are faulty. Do not use the bearings again.
- Inspect the front output shaft front bearing for being faulty. Refer to
Transfer Case Cleaning and Inspection.
- Using a hammer and a punch, remove the front bearing for the front output shaft from the front case.
- Clean and inspect all the internal parts of the transfer case. Refer to
Transfer Case Cleaning and Inspection.