Transfer Case - Vehicles With: 1-Speed Torque On Demand Transfer Case: Disassembly

WARNING: This page is about a different variant/trim than selected.

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.

Using a transmission adjustable mounting arm, secure the transfer case to the bench. Clean the transfer case with solvent and dry with compressed air. Use the General Equipment: Adjustable Mounting Arm

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Remove the transfer case rear seal. Refer to: Transfer Case Rear Seal .
Remove the coil wire pin from the electrical connector.

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Remove the coil nuts and washers.

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NOTE: The transfer case bolts are self tapping, and it is normal to find metal shavings while removing the cover.

Remove the transfer case bolts.

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Using the pry bosses, separate the transfer case covers.

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Remove the transfer case field coil.

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Remove the coil housing snap ring and spacer.

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Remove the caged thrust bearing assembly.
- Install a new bearing as necessary.
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Remove the coil housing.

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Remove the steel balls and the cam.

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Remove the wave spring.

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Remove clutch pack circlip.

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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 and armature must be installed. Failure to install a new clutch pack can result in component failure.

Remove the clutch pack assembly with the armature.

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Remove the clutch pack spacer.

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Remove the drive chain and the sprockets as an assembly.
- Install new components as necessary.
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Remove the output shaft sprocket spacer.

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Remove the thrust bearing assembly.
- NOTE: The upper thrust washer may be attached to the sprocket.
  
  Remove the thrust washer.
- Remove the thrust bearing.
- Remove the thrust washer.
- Install new components as necessary.
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Remove the magnet from its slot in the case.

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NOTE: The pump assembly is not repairable.

Remove the oil pump assembly.

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Remove the output shaft.

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Remove and discard the front input shaft seal.

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Remove the input shaft bearing.

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NOTE: Do not let the front output shaft fall while removing the snap ring or damage to the component may occur.

Remove the output shaft circlip and the output shaft.

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Remove and discard front output shaft seal.

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Clean and inspect the components of the transfer case for damage and install new components as necessary.