Tools Required

1. Using the adapter studs, attach the J 45759 to the transfer case. All of the transfer case disassembly procedures can be performed with the case mounted to the J 45759 .



2. Mount the J 3289-20  (1) to a sturdy workbench.
3. Install the J 45759  (2) into J 3289-20  (1) and secure with pivot pin.



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



5. Remove the encoder motor bracket bolt (2).
6. Remove the encoder motor mounting bolts (1).
7. Remove the encoder motor assembly (3).



8. Remove the rear vehicle speed sensor (VSS) and the O-ring seal.

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




9. Using the J 2619-01  (1) and the J 45278 (2), remove the rear output shaft seal.



10. Install the J 8614-01 to the front output shaft flange.
11. Hold the J 8614-01 and loosen the front output shaft flange nut.



12. Remove the front output shaft flange nut (1).
13. Remove the front output shaft flange washer (2).
14. Remove the front output shaft flange seal (3).
15. Remove the front output shaft flange (4).



16. Using the J 6125-1B  (1) and the J 23129  (2), remove the front output shaft seal.



17. Remove the transfer case retaining bolts and washers.

Mark the location of the brackets.

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




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



20. Remove the rear case half from the front case half. The rear output shaft is removed with the rear case half.



21. Remove the shift fork shaft spring.



22. Remove the rear output sun gear.



23. Remove the rear output shaft thrust washer.



24. Remove the planetary differential assembly.



25. Remove the front output sun gear.




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.

26. Remove the chain with the drive sprocket and driven sprocket.



27. Remove the lockup shift collar assembly and lockup mode shift fork.



28. Remove the lockup mode shift fork from the lockup shift collar assembly.



29. Disassemble the lockup shift collar assembly, if necessary.

29.1.

Remove the retainer ring from the sleeve.

29.2.

Remove the hub.

29.3.

Remove the spring.




30. Remove the inner lockup hub.



31. Remove the upper thrust washer.



32. Remove the magnet.



33. Remove the center bearing support.



34. Remove the lower thrust washer.



35. Using a pair of needle-nose pliers, spread the snap ring in order to remove the bearing from the support, if necessary.



36. Remove the oil pump assembly with the hose and screen.



37. Disconnect the oil pump hose from the oil pump screen.
38. Disconnect the oil pump hose from the oil pump.



39. Remove the shift fork shaft.




Notice: In order to prevent component damage, properly remove and install the shift cam and shaft assembly. When removing or installing the shift cam and shaft assembly, keep the shaft straight and do not tilt. Tilting the shift cam and shaft assembly in the transfer case housing will break the tip on the end of the shaft.

40. Remove the shift cam and shaft assembly.

40.1.

Rotate the high/low shift fork roller from the shift cam.

40.2.

Lift straight up on the shift cam and shaft assembly.




41. Remove the mainshaft.



42. Remove the high/low range sleeve with the high/low range shift fork.



43. Remove the range shift fork from the range shift sleeve.



44. Remove the input shaft needle thrust bearing.



45. Remove the 4494 (1) or the 4493 (2) high/low planetary carrier.



46. Inspect the 4494 (1) or the 4493 (2) mainshaft front support bearing (3) for being faulty. Refer to Transfer Case Cleaning and Inspection .
47. Using a brass drift and a hammer, remove the mainshaft front support bearing (3) from the planetary carrier assembly.



48. Remove the front output shaft assembly.



49. Using a hammer and a suitable punch, remove the input shaft seal.



50. Using a hammer and a brass drift, remove the input gear bearing from the front case half.



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



52. Remove the ring gear retaining ring.



53. Remove the ring gear from the front case half.



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



55. Using the J 45380 , remove the rear output shaft bushing.



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

56.1.

Spread the rear output shaft rear bearing outer retaining ring.

56.2.

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




57. Using a hydraulic press and the J 22912-B , remove the speed sensor tone wheel.

Do not use the speed sensor tone wheel again.




58. Remove the rear output shaft bearing retaining ring.



59. Using a hydraulic press, remove the rear output shaft bearing.



60. Inspect the mainshaft rear support bushing, in the rear output shaft, for being faulty. Refer to Transfer Case Cleaning and Inspection .
61. Using the J 2619-01  (1) and the J 45548  (2), remove the mainshaft rear support bushing from the rear output shaft.



62. Using the J 29369-1  (1) and the J 23907  (2), remove the front output shaft rear bearing from the rear case.



63. Remove the shift shaft seal by prying it out of the case.