1

Transfer Case Nuts

Special Tools

J 45759 Assembly Fixture

2

Transfer Case

Special Tools

J 3289-20 Holding Fixture

3

Pivot Pin

Tip

1

Transfer Case Two/Four Wheel Drive Actuator Bolt/Screw

2

Transfer Case Two/Four Wheel Drive Actuator Assembly

3

Transfer Case Oil Fill Plug

4

Transfer Case Oil Drain Plug

5

Transfer Case Vent

Tip
Remove ONLY if the vent pipe is damaged.

6

Vehicle Speed Sensor Assembly

7

Vehicle Speed Sensor O-Ring Seal

8

Transfer Case Access Hole Plugs (Qty: 2)

1

Transfer Case Rear Output Shaft Seal

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

2

Transfer Case Shift Detent Plunger Plug

3

Transfer Case Shift Detent Plunger Plug Seal

4

Transfer Case Shift Detent Spring

5

Transfer Case Shift Detent Plunger

1

Transfer Case Bolts (Qty: 17)

2

Transfer Case Bracket

3

Transfer Case Rear Case Half

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

Tip

4

Transfer Case Two/Four Wheel Drive Actuator Seal

1

Transfer Case Shift Fork Spring

2

Transfer Case Oil Pump Suction Pipe

3

Transfer Case Oil Pump Suction Pipe Seal

1

Transfer Case Rear Output Shaft Assembly

Tip
Mount the assembly into a soft-jaw vice or holding fixture for disassembly.

2

Transfer Case Two/Four Wheel Drive Shift Fork Assembly

3

Transfer Case High/Low Shift Fork Assembly

4

Transfer Case High/Low Clutch

5

Transfer Case Front Output Shaft Drive Chain Assembly

1

Transfer Case Rear Output Shaft Rear Bearing Retaining Ring

2

Transfer Case Rear Output Shaft Rear Bearing Assembly

Tip
Use an arbor press or suitable puller to remove the bearing from the rear output shaft.

3

Transfer Case Rear Output Shaft Rear Bearing Retaining Ring

4

Transfer Case Rear Output Shaft Speed Reluctor Wheel

5

Transfer Case Oil Pump Assembly

6

Transfer Case Front Output Shaft Drive Sprocket Retaining Ring

7

Transfer Case Front Output Shaft Drive Sprocket Spacer - Rear

8

Transfer Case Front Output Shaft Drive Sprocket

9

Transfer Case Front Output Shaft Drive Sprocket Bearing Assembly (Qty: 2)

Tip
Only remove the bearing if faulty. Refer to Drive Chain, Drive Sprocket, and Driven Sprocket Cleaning and Inspection .

10

Transfer Case Two/Four Wheel Drive Synchronizer Blocking - Inner - Ring

11

Transfer Case Two/Four Wheel Drive Synchronizer Blocking - Outer - Ring

12

Transfer Case Two/Four Wheel Drive Synchronizer Assembly

13

Transfer Case Two/Four Wheel Drive Synchronizer Sleeve

14

Transfer Case Two/Four Wheel Drive Synchronizer Insert (Qty: 3)

15

Transfer Case Two/Four Wheel Drive Synchronizer Hub

16

Transfer Case Rear Output Shaft

1

Transfer Case Input Shaft Seal

2

Transfer Case Input Shaft Bearing Outer Retaining Ring

Caution: Do not rotate the transfer case while the retaining ring is removed. Rotating the transfer case while the retaining ring is removed, may cause the input shaft/planetary assembly to fall from the transfer case, resulting in personal injury.

3

Transfer Case Input Shaft/Planetary Assembly

4

Transfer Case High/Low Planetary Carrier Retaining Ring

5

Transfer Case High/Low Locking Plate

6

Transfer Case Planetary Carrier Sun Gear Thrust Washer

7

Transfer Case Input Shaft

8

Transfer Case Input Shaft Pilot Bearing Retaining Ring

9

Transfer Case Input Shaft Pilot Bearing Assembly

Tip
Only remove the bearing if faulty. Refer to Front Output Shaft and Input Shaft Cleaning and Inspection .

10

Transfer Case Planetary Carrier Sun Gear Thrust Washer

11

Transfer Case High/Low Planetary Carrier Assembly

12

Transfer Case Input Shaft Inner Retaining Ring

13

Transfer Case Input Shaft Bearing Assembly

1

Transfer Case Front Case Half

Tip
Place the front case half on an arbor press.

2

Transfer Case Front Output Shaft Assembly

Tip
Press the front output shaft assembly from the front case half using an arbor press or soft-face hammer.

3

Transfer Case Front Output Shaft Seal