Disassembly
EXTERNAL COMPONENTS
Clean
^ The transfer case exterior using a solvent and a stiff brush.
Fig. 17 Rear Case Half. New Process Models 231, 233 & 241 Transfer Cases:
Fig. 18 Front Case Half. New Process Models 231, 233 & 241 Transfer Cases:
Fig. 19 Transfer Case Exploded View. New Process Models 231, 233 & 241 Transfer Cases:
Remove or Disconnect
1. Front output flange nut (77), washer (76), rubber sealing washer (75), and front output flange (74) from the front output shaft.
2. Four-wheel drive actuator switch (46) and O-ring seal (47).
3. Speedometer sensor (9) and O-ring seal (85).
4. Poppet screw (68), O-ring seal (69), poppet spring (71), and poppet plunger 1701.
MAINSHAFT EXTENSION AND OIL PUMP HOUSING
Fig. 19 Transfer Case Exploded View. New Process Models 231, 233 & 241 Transfer Cases:
Remove or Disconnect
1. Rear extension housing bolts (3) and rear extension (4).
2. Bearing retainer (snap ring) (5) from the mainshaft (19).
3. Pump retainer housing bolts (7).
^ Pump retainer bolts are shouldered.
4. Pump retainer housing (6) from the rear case half (17).
5. Retainer (snap ring) (10), speedometer tone wheel (11), and retainer (snap ring) (10) from mainshaft (19).
6. Case bolts (3) from case halves.
^ Note two longer case bolts (16) and washers (27) go into the doweled case holes (33).
^ Separate the case halves. Insert two screwdrivers into the slots cast into the case ends and pry apart. Do not attempt to wedge the case halves span at any point on the mating surfaces.
^ Be careful not to damage the oil pump (12) (located in the rear case half) (17).
INTERNAL COMPONENTS
Fig. 19 Transfer Case Exploded View. New Process Models 231, 233 & 241 Transfer Cases:
Fig. 20 Oil Pump, Pickup Tube & Screen. New Process Models 231, 233 & 241 Transfer Cases:
Fig. 21 Mode Fork & Shaft Assembly. New Process Models 231, 233 & 241 Transfer Cases:
Fig. 22 Shift Rail Assembly. New Process Models 231, 233 & 241 Transfer Cases:
Fig. 23 Input Gear Bearing Removal. New Process Models 231, 233 & 241 Transfer Cases:
Fig. 24 Front Output Shaft Rear Bearing Removal. New Process Models 231, 233 & 241 Transfer Cases:
Remove or Disconnect
Tools Required:
J 2619-01 Slide Hammer
J 8092 Driver Handle
J 22912-1 Bearing Remover
J 29369-1 Output Shaft Bearing Remover
J 29369-2 Output Shaft Bearing Remover
J 9276-21 Slide Hammer adapter
J 33832 Bearing Installer/Remover
NOTICE: The annulus gear found in this transfer case is not serviceable or removable and should only be replaced as a unit with the front case half. It the annulus gear Is removed, damage will result to the case.
Fig. 20 Oil Pump, Pickup Tube & Screen. New Process Models 231, 233 & 241 Transfer Cases:
1. Oil pump (12), pickup tube (18), O-ring (14), and pump pickup filter (35) from the rear case half (17).
2. Fork shift spring (52).
3. Retainer (snap ring) (23) from the front output shaft (21).
4. Mainshaft (19), chain (58), and driven sprocket (22) from the front case halt (45) as a unit.
^ Mode shift fork (54) and shift rail (48) will be removed with the mainshaft.
5. Retainer (snap ring) (83) from the mainshaft (19).
Fig. 21 Mode Fork & Shaft Assembly. New Process Models 231, 233 & 241 Transfer Cases:
6. Synchronizer assembly (81) and drive sprocket (20) from the mainshaft (19).
Fig. 22 Shift Rail Assembly. New Process Models 231, 233 & 241 Transfer Cases:
7. Range shift fork (61), and range shift hub (34), from planetary carrier (36).
^ It is necessary to rotate the sector with shaft (65) to obtain clearance when removing the range fork (51).
8. Shift lever nut (63), washer (64), shift lever (65), sector and shaft (55), plastic washer (66), and 0-ring (67) from the front case half (45).
9. Input bearing retainer bolts (43) and input bearing retainer (44) from front case half (46).
10. Retainer ring (snap ring) (41) from input gear (38).
11. Bearing retainer (snap ring) (39).
12. Planetary carrier (86) and input gear (88) from the annulus gear using a soft faced hammer.
13. Input bearing (40) from the front case half (45) using J 36370 and J 8092.
A. Snap ring (87)
B. Carrier lock ring (78).
C. Thrust washer (37).
14. Drive sprocket bearings (82) from drive sprocket (20) using J 29369-1 and J 2619-01.
Fig. 23 Input Gear Bearing Removal. New Process Models 231, 233 & 241 Transfer Cases:
15. Mainshaft pilot bearing (84) from the input gear (38) using J 29369-2, J 9276-21, and J 2619-01.
16. Front output bearing retainer (snap ring) (60).
17. Front output shaft seal (72) from front case half (45).
18. Front output bearing (61) from front case half (45) using J 33832 and J 8092.
19. Seal (1) from the mainshaft extension housing (4).
20. Seal (42) from input bearing retainer (44).
Fig. 24 Front Output Shaft Rear Bearing Removal. New Process Models 231, 233 & 241 Transfer Cases:
21. Front output bearing (24) from rear case half (17).
A. Insert J 29369-2 behind the needle bearings.
B. Using J 2619-01, hammer the bearing from the case.
22. Mainshaft bearing (6) from the oil pump retainer (8).
23. Magnet (26) from the front case half (45).
Disassemble
^ Scribe the location of the synchronizer sleeve and hub to aid in assembly.
1. Main drive synchronizer stop ring (28) from the synchronizer sleeve (29).
2. Spring retainers (32) from the synchronizer hub (31).
3. Synchronizer hub (31) from the synchronizer sleeve (29).
^ Be careful not to damage the synchronizer struts (30) when removing the sleeve (29) from the hub (31).
^ The oil pump (12) is not serviceable and should be replaced as a unit only.