Transfer Case Disassemble

Transfer Case Disassemble

Oil Drain Plug Removal





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

Oil Fill Plug Removal





Remove and discard the oil fill plug (1) and seal.

Transfer Case Vent Removal





Remove the transfer case vent hose connector (1), as required.

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), using multi-grip pliers as required-RPO MXE.

Front Wheel Drive Intermediate Shaft Removal

Special Tools

* DT-113-2-A - Holder

* DT-622-A - Transmission Bracket

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




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




2. Remove the first design dirt deflector (1). Install a sheet metal screw (2) into the outer surface of the first design dirt deflector and remove with suitable pliers.

3. Remove the second design dirt deflector (3). Remove the inner metal portion first using a prying type tool and then remove the outer portion by installing a sheet metal screw into surface and removing with suitable pliers. Refer to New Product Information Description and Operation for additional information.

4. Discard the seal assembly (1).




5. Remove the transfer case intermediate shaft retaining ring (1), using suitable snap ring pliers.




6. Remove the transfer case intermediate shaft (1), with bearing, using a rubber mallet.

Front Wheel Drive Intermediate Shaft Bearing Removal

Special Tools

DT-307-B - Remover Plate

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




1. Remove the transfer case intermediate shaft bearing retaining ring (2) from intermediate shaft (1), using suitable pliers.




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




3. Remove the second design intermediate shaft O-ring (3), as required. Refer to New Product Information Description and Operation for additional information.

Rear Output Shaft Seal Removal





Note: Be sure to only pry against the five flat bosses on the rear output shaft housing.

1. Remove the inner metal sleeve (1) from the seal by working a screwdriver around the perimeter of the sleeve, prying only against the flat bosses of the output shaft housing.





Note:

* Be sure to only pry against the five flat bosses on the rear output shaft housing.

* The seal tension spring (2) may fall off as the seal is removed.

2. Remove the rear output shaft seal (1) by working a sharpened chisel around the perimeter of the seal, prying only against the flat bosses of the output shaft housing.

3. Ensure the seal tension spring (2) is removed from the bore.

Rear Output Shaft Housing Removal





Note:

* Do not attempt to remove the rear output shaft housing (1) or bolts (2) from the transfer case assembly.

* The rear output shaft, shaft bearings, housing (1) and housing O-ring seal are not serviceable components.

The rear output shaft seal (3) is a serviceable component. Refer to Rear Output Shaft Seal Removal and Rear Output Shaft Seal Installation.

Rear Extension Housing Removal




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




2. Remove the rear extension housing (2) and bolts (3).




3. Remove and discard the rear extension housing-to-transfer case seal (1).

Input Shaft and Idler Shaft Removal




1. Remove the input shaft (3)

2. Remove the idler gear (2).

3. Remove the idler gear shaft (1)-RPO MXE.

Input Shaft Bearing Retainer Front Seals Removal





Note: There are two input shaft front seals located in the transfer case housing.

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





Note: There are two input shaft front seals located in the transfer case housing.

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

Idler Gear Shaft Front Seal Removal





Remove the transfer case idler gear shaft front seal (1) from transfer case. - RPO MXE

Idler Gear Shaft Rear Seal Removal





Remove the transfer case idler gear shaft rear seal (1) from the rear extension housing. - RPO MXE

Input Shaft Bearing Retainer Rear Seal Removal





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

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

Front Wheel Drive Intermediate Shaft Seal Removal





Remove the intermediate shaft seal (1) from the rear extension housing using a suitable screw driver.