Transfer Case - 2-Speed Torque-On-Demand: Disassembly
- 1.
Clean the transfer case exterior with solvent and dry with compressed air.
NOTE:
Seal all openings before cleaning the transfer case exterior. This will prevent entry of dirt and water, which may cause damage to internal components.
- 2.
Using the Transmission Holding Fixture, secure the transfer case to a work bench. Rotate the transfer case so that the output shaft is pointing upward.
- 5.
Remove the coil wire pin from the electrical connector.- Remove the wire connector inner retainer.
- Press the release tab and remove the coil wire pin (tan wire).
- 9.
Remove the 20 transfer case cover bolts.
NOTE:
It is normal to find metal shavings after removing the self-tapping transfer case bolts.
- 11.
Using the Bearing Cup Remover and the Slide Hammer, remove the rear output shaft support bearing.- Inspect the bearing for wear or damage. Install a new bearing as necessary.
- 12.
Using the Bearing Cup Remover and the Slide Hammer, remove the front output shaft rear bearing.- Inspect the bearing for wear or damage. Install a new bearing as necessary.
- 13.
Remove the snap ring.- Inspect the snap ring for wear or damage. Install a new snap ring as necessary.
- 14.
Remove the caged thrust bearing assembly.- Inspect the bearing for wear or damage. Install a new bearing as necessary.
- 19.NOTE: When removing the clutch pack assembly, do not separate the clutch pack assembly. Keep tension on the clutch pack during removal. Set the clutch pack assembly on the bench in the same position as located in the transfer case. The thrust washer in the lower clutch pack uses tabs to hold it in place. If the thrust washer is not in place, a transfer case clearance problem will occur.NOTE: If the clutch pack is disassembled, a new clutch pack must be installed and the armature transferred. Failure to install a new clutch pack can result in component failure.
Remove the clutch pack assembly with the armature.
- 20.
Remove the drive chain and the sprockets as an assembly.- Inspect the drive chain for wear or damage. Inspect the sprockets for broken or cracked teeth. Install new components as necessary.
- 21.
Remove the thrust bearing assembly.- 1.
Remove the thrust washer.- The upper thrust washer may be attached to the sprocket.
- 2.
Remove the thrust bearing.
- 3.
Remove the thrust washer.
- Inspect the washers and bearing for wear or damage. Install new components as necessary.
- 1.
- 26.
Remove the reduction shift fork, the reduction hub and the shift cam as an assembly.- Separate and inspect the reduction hub and the reduction shift fork for wear or damage. Do not disassemble the shift cam assembly.
- 29.
Remove the ring gear.- 1.
Remove the snap ring.- Inspect the snap ring for wear or damage. Install a new snap ring as necessary.
- 2.
Remove the ring gear.
- 1.
- 30.
Remove the snap ring and the front output shaft.- Inspect the snap ring for wear or damage. Install a new snap ring as necessary.
NOTE:
Do not let the front output shaft fall when removing the snap ring.
- 31.
Remove and discard the front output shaft oil seal.
NOTE:
Carefully remove the seal, do not damage the seal bore.
- 32.
Remove and discard the front input shaft seal.
NOTE:
Carefully remove the seal, do not damage the seal bore.
- 34.
Remove the front output shaft support bearing.- Inspect the bearing for wear or damage. Install a new bearing as necessary.