1

Transfer Case Nuts

Special Tools

J 45759 Assembly Fixture

For equivalent regional tools, refer to Special Tools.

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

Caution: Refer to Transfer Case Seal Removal Caution 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

Caution: Refer to Machined Surface Damage Caution 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

Warning: 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