Internal Components

- Tools Required:
- J 8092 Driver Handle
- J 36370 Bearing Installer/Remover
- J 29170 Bearing Remover
- J 29369-1 Bearing Remover
- J 9276-21 Adapter
- J 2619-01 Slide Hammer
- J 33790 Bearing Remover

REMOVE OR DISCONNECT

Important: 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. If the annulus gear is removed, damage will occur to the case.





1. Oil pump from the pickup tube and rear case half.





2. Oil pump pickup tube, O-ring, and pump pickup filter from the rear case half.





3. Mode fork shift spring from the shift rail.
4. Front output shaft seal from the front case half.





5. Front output shaft snap ring.





6. Mainshaft, drive chain, and driven sprocket from the front case half as an assembly.
- Mode shift fork and shift rail will be removed with the mainshaft.





7. Synchronizer to mainshaft snap ring.





8. Synchronizer assembly from the mainshaft.
9. Drive sprocket from the mainshaft.





10. Range shift fork and range shift hub from the planetary carrier.
- It is necessary to rotate the selector shaft to obtain clearance when removing the range fork.





11. Shift lever nut, washer, shift lever, selector and shaft assembly, plastic washer, and the O-ring seal from the front case half.





12. Input bearing retainer bolts and input bearing retainer from the front case half.





13. Input gear snap ring.





14. Input and low range gear assembly from the annulus gear using a soft faced hammer.





15. Input gear to the low range gear assembly snap ring.
16. Input gear from the low range gear assembly.
17. Input bearing from the front case half using J 36370 and J 8092.





18. Needle bearings from the input gear using J 29369-1, J 9276-21 and J 2619-01.





19. Front output bearing snap ring.
20. Front output bearing from the front case half using J 33790 and J 8092.
21. Seal from the mainshaft extension housing.
22. Seal from the input bearing retainer.





23. Front output rear bearing from the rear case half using J 2619-01 and J 29369-2.
24. Mainshaft bearing from the oil pump retainer using J 33790.





25. Magnet from the front case half.

DISASSEMBLE
Mark the location of the synchronizer hub and sleeve to aid in assembly. Synchronizer teeth must align with struts.





1. Main drive synchronizer stop ring from the synchronizer sleeve.
2. Spring retainers from the synchronizer hub.
3. Synchronizer hub from the synchronizer.
4. Oil pump screws from the oil pump.

Important: The oil pump is serviced by replacement only.