Transfer Case Disassemble

Transfer Case Disassemble

Special Tools

* DT-113-A - Bracket

* DT-307-B - Remover Plate

* DT-622-A - Adapter

For equivalent regional tools, refer to Special Tools Tools and Equipment.





Secure the transfer case (3) in DT-113-A - bracket (1), using the DT-622-A - adapter (2).

Drain Plug Removal





Remove and DISCARD the oil drain plug (1) and seal.

Fill Plug Removal





Remove and DISCARD the fill plug (1) and seal.

Transfer Case Vent Removal




1. Remove vent pipe bolt (1), if applicable.

2. Remove transfer case vent pipe (2) and vent pipe seal (3), if applicable.

Transfer Case-to-Transmission Seal Removal





Remove and discard the transfer case-to-transmission seal (1).

Locating Bushing Removal





Remove the transfer case locating bushing (1) as required using multigrip pliers.

Intermediate Drive Shaft Removal




1. Remove the front wheel drive intermediate shaft dirt deflector (1) - model dependant.




2. Remove the intermediate drive shaft retaining ring (1).




3. Remove the intermediate drive shaft (1), using a rubber mallet.

Intermediate Drive Shaft Bearing Removal




1. Remove the transfer case intermediate gear bearing retaining ring (1).




2. Remove the transfer case intermediate drive shaft bearing (1), using the DT-307-B - remover plate (2) and a hydraulic press.




3. Remove the transfer case intermediate gear bearing retaining ring (2) as required.

Rear Output Shaft Seal Dirt Deflector Removal





Remove the rear output shaft seal dirt deflector (1), using a screw driver.

Rear Output Drive Shaft Seal Removal




1. Install a sheet metal type screw (2) into the face of the rear output seal.

2. Remove the rear output drive shaft seal (1) with multigrip pliers.

Rear Output Drive Shaft Housing O-ring Seal Removal




1. Remove the 7 transfer case rear output drive shaft housing bolts (1).

2. Remove the transfer case rear output drive shaft housing (2).

3. Remove the transfer case rear output drive shaft housing seal (3).

4. Clean all of the sealing surfaces.

Input Shaft Removal




1. Remove the transfer case rear extension housing bolts (1) and rear extension housing (2).




2. Remove the rear extension housing (2) from the transfer case housing (1).




3. Remove the input shaft (1).

Note: The bearings, shafts, gears, and housings are not serviceable components. If damage to any of those components is present, the transfer case must be replaced as an assembly.

4. Remove the intermediate drive shaft seal (2) from the input shaft.

Idler Shaft Removal





Remove the idler shaft (1) from the housing.

Input Shaft Seals Removal




1. Remove the transfer case input shaft front (inner) seal (1) using a suitable screw driver.




2. Remove the transfer case input shaft front (outer) seal (1) using a suitable screw driver.





Note: To avoid damage to the housing, use a brass punch to remove the seal.

3. Remove the transfer case input shaft rear seal (1) from the rear extension housing.