1

Attachment Nuts

Special Tools

J 45759 Assembly Fixture

2

Transfer Case

Special Tools

J 3289-20 Holding Fixture

3

Pivot Pin

Tip

1

Vehicle Speed Sensor

2

Vehicle Speed Sensor O-Ring

3

Transfer Case Oil Fill Plug

4

Transfer Case Oil Drain Plug

5

Transfer Case Vent Pipe

Tip
Remove ONLY if the vent pipe elbow is damaged.

1

Transfer Case Rear Output Shaft Seal

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

2

Transfer Case Extension Bushing

Procedure

1. Install the finger section of the J 45380 in front of the bushing.
2. Install the tube and forcing screw assembly into the finger section. Ensure the forcing screw is backed out.
3. Using a wrench on the forcing screw, remove the bushing.

Tip
Only remove the bushing if fault is found. Refer to Rear Output Shaft Rear Bearing Retainer Cleaning and Inspection .

Special Tools

J 45380 Transfer Case Rear Bushing Remover and Installer

1

Transfer Case Bolts (Qty: 23)

2

Transfer Case Rear Output Shaft Rear Bearing Retainer Assembly

3

Transfer Case Rear Output Shaft Speed Reluctor Wheel

Tip
Discard the rear output shaft speed reluctor wheel after removal.

Special Tools

4

Transfer Case Oil Pump Cover Bolts (Qty: 6)

5

Transfer Case Oil Pump Cover

6

Transfer Case Oil Pump Driven Gear

7

Transfer Case Oil Pump Drive Gear

1

Transfer Case Bolts (Qty: 23)

2

Transfer Case Front Shaft Side Bracket

3

Transfer Case Mainshaft Side Bracket

4

Transfer Case Rear Case Half

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

Special Tools

J 45358 Case Spreader

1

Transfer Case Chip Collector Magnet

2

Transfer Case Oil Pump Suction Pipe

3

Transfer Case Oil Pump Hose

4

Transfer Case Oil Pump Screen

5

Transfer Case Oil Pump Suction Pipe O-Ring Seal

6

Transfer Case Rear Output Shaft Bearing Assembly

Tip
Only remove the bearing if faulty. Refer to Transfer Case Rear Half Cleaning and Inspection .

7

Transfer Case Front Output Shaft Rear Bearing

Tip
Only remove the bearing if faulty. Refer to Transfer Case Rear Half Cleaning and Inspection .

1

Transfer Case Rear Output Shaft

2

Transfer Case Two/Four Wheel Drive Chain

Tip

3

Transfer Case Two/Four Wheel Drive Driven Sprocket Outer Retaining Ring

4

Transfer Case Two/Four Wheel Drive Driven Sprocket

5

Transfer Case Front Output Shaft Bearing Retaining Yoke Ring

6

Transfer Case Shaft to Yoke Seal

7

Transfer Case Front Output Shaft

8

Transfer Case Two/Four Wheel Drive Sprocket Outer Retaining Ring

9

Transfer Case Front Output Shaft Drive Sprocket

10

Transfer Case Front Output Shaft Drive Sprocket Bearing

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

11

Transfer Case Four Wheel Drive Clutch Hub Assembly

1

Front/Rear Drive Differential Carrier Assembly

2

Transfer Case Input Shaft Thrust Bearing Washer

3

Transfer Case Wave Washer

4

Transfer Case Input Shaft

Tip
It may be necessary to use a soft-face hammer.

5

Transfer Case Input Gear Thrust Bearing

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

6

Transfer Case Input Shaft Seal

7

Transfer Case Front Output Shaft Seal

8

Transfer Case Front Output Shaft Front Bearing

Tip
Only remove the bearing if faulty. Refer to Transfer Case Front Half Cleaning and Inspection .

9

Transfer Case Front Input Double Row Ball Bearing

Tip
Only remove the bearing if faulty. Refer to Transfer Case Front Half Cleaning and Inspection .