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Service Information: Disassembly

Fig 1: Identifying Fill And Drain Plugs And Shift Motor Locations
GC0027439Courtesy of DAIMLERCHRYSLER CORP.
1 - FILL PLUG
2 - DRAIN PLUG
3 - SHIFT MOTOR AND MODE SENSOR ASSEMBLY
  1. Place the transfer case in a shallow pan and remove the fill (1) and drain (2) plugs to drain the remainder of the fluid. See Fig 1.
    Fig 2: Rear Output Shaft Nut Removal/Installation
    GC0027440Courtesy of DAIMLERCHRYSLER CORP.
    1 - HOLDER C-3281
    2 - REAR COMPANION FLANGE
  2. Using Holder C-3281 (1), remove the rear flange (2) nut. See Fig 2.
    Fig 3: Rear Output Shaft Flange Removal/Installation
    GC0027441Courtesy of DAIMLERCHRYSLER CORP.
    1 - REAR COMPANION FLANGE
    2 - OUTPUT SHAFT
  3. Remove the rear output flange (1) from the main shaft (2). If necessary, use a suitable 2 or 3 jaw puller to remove the output flange. See Fig 3.
    Fig 4: Shift Motor Bolts Removal/Installation
    GC0027442Courtesy of DAIMLERCHRYSLER CORP.
    1 - BOLTS
    2 - SHIFT MOTOR AND MODE SENSOR ASSEMBLY
  4. Remove the bolts (1) holding the shift motor and mode sensor assembly (2) to the transfer case. See Fig 4.
    Fig 5: Shift Motor Removal/Installation
    GC0027443Courtesy of DAIMLERCHRYSLER CORP.
    1 - SHIFT MOTOR AND MODE SENSOR ASSEMBLY
    2 - SHIFT SECTOR
    3 - TRANSFER CASE
  5. Remove the shift motor and mode sensor assembly (1) from the shift sector (2) and the transfer case (3). See Fig 5.
    Fig 6: Rear Retainer Bolts Removal/Installation
    GC0027444Courtesy of DAIMLERCHRYSLER CORP.
    1 - REAR HOUSING
    2 - REAR COVER
    3 - BOLTS
  6. If necessary, remove the bolts holding the transfer case damper to the transfer case and remove the damper.
  7. Remove the bolts (3) holding the rear cover (2) onto the rear housing (1). See Fig 6.
    Fig 7: Rear Retainer Removal/Installation
    GC0027445Courtesy of DAIMLERCHRYSLER CORP.
    1 - REAR COVER
    2 - REAR HOUSING
    NOTE: Use the pry slots provided and take care not to damage the sealing surface.
  8. Remove the rear cover (1) from the rear housing (2). See Fig 7.
    Fig 8: Remove Sector Roller Roll-pin
    GC0027446Courtesy of DAIMLERCHRYSLER CORP.
    1 - REAR HOUSING
    2 - ROLL-PIN
    3 - SHIFT RAIL
    4 - SECTOR ROLLER
    NOTE: Rotate the sector upward to ease the removal of the roll-pin.
  9. Using a suitable punch, remove the roll-pin (2) holding the sector roller (4) to the shift rail (3). See Fig 8.
    Fig 9: Sector Roller Removal/Installation
    GC0027447Courtesy of DAIMLERCHRYSLER CORP.
    1 - SECTOR ROLLER
    2 - SHIFT RAIL
  10. Remove the sector roller (1) from the shift rail (2). See Fig 9.
    Fig 10: Anti-Rotation Bracket Removal/Installation
    GC0027448Courtesy of DAIMLERCHRYSLER CORP.
    1 - ANTI-ROTATION BRACKET
    2 - SHIFT RAIL
  11. Remove the anti-rotation bracket (1) from the shift rail (2). See Fig 10.
    Fig 11: Clutch Lever Rail Plug Removal/Installation
    GC0027449Courtesy of DAIMLERCHRYSLER CORP.
    1 - CLUTCH LEVER RAIL PLUG
  12. Remove the clutch lever rail plug (1) from the rear housing. See Fig 11.
    Fig 12: Clutch Lever Rail Removal/Installation
    GC0027450Courtesy of DAIMLERCHRYSLER CORP.
    1 - REAR HOUSING
    2 - CLUTCH LEVER RAIL
  13. Remove the clutch lever rail (2) from the rear housing (1). See Fig 12.
    Fig 13: Oil Pump Inner Rotor Removal/Installation
    GC0027452Courtesy of DAIMLERCHRYSLER CORP.
    1 - OUTPUT SHAFT
    2 - OIL PUMP INNER ROTOR
    3 - REAR HOUSING
  14. Remove the oil pump inner rotor (2) from the main shaft (1) and rear housing (3). See Fig 13.
    Fig 14: Oil Pump Outer Rotor Removal/Installation
    GC0027453Courtesy of DAIMLERCHRYSLER CORP.
    1 - OUTPUT SHAFT
    2 - OIL PUMP OUTER ROTOR
    3 - REAR HOUSING
  15. Remove the oil pump outer rotor (2) from the main shaft (1) and rear housing (3). See Fig 14.
    Fig 15: Rear Output Bearing Inner Retaining Ring Removal/Installation
    GC0027454Courtesy of DAIMLERCHRYSLER CORP.
    1 - OUTPUT SHAFT
    2 - RETAINING RING
    3 - REAR HOUSING
    NOTE: Pull upward on the main shaft to ease the removal of the main shaft retaining ring.
  16. Remove the rear output shaft (1) retaining ring (2). See Fig 15.
    Fig 16: Rear Housing Bolts Removal/Installation
    GC0027451Courtesy of DAIMLERCHRYSLER CORP.
    1 - REAR HOUSING
    2 - BOLTS
    3 - FRONT HOUSING
  17. Remove the bolts (2) holding the rear housing (1) to the front housing (3). See Fig 16.
    Fig 17: Rear Housing Removal/Installation
    GC0027455Courtesy of DAIMLERCHRYSLER CORP.
    1 - REAR HOUSING
    2 - FRONT HOUSING
    NOTE: Some prying may be necessary to break the seal between the front and rear case. Use care to not damage the sealing surfaces.
  18. Remove the rear housing (1) from the front housing (2). See Fig 17.
    Fig 18: Clutch Lever Assembly Removal/Installation
    GC0027456Courtesy of DAIMLERCHRYSLER CORP.
    1 - CLUTCH LEVER ASSEMBLY
  19. Remove the clutch lever assembly (1) from the mainshaft and shift rail. See Fig 18.
    Fig 19: Thrust Bearing Support Plate Retaining Ring Removal/Installation
    GC0027457Courtesy of DAIMLERCHRYSLER CORP.
    1 - OUTPUT SHAFT
    2 - RETAINING RING
  20. Remove the thrust bearing support plate retaining ring (2) from the main shaft (1). See Fig 19.
    Fig 20: Thrust Bearing Support Plate Removal/Installation
    GC0027458Courtesy of DAIMLERCHRYSLER CORP.
    1 - OUTPUT SHAFT
    2 - SUPPORT PLATE
  21. Remove the thrust bearing support plate (2) from the main shaft (1). See Fig 20.
    Fig 21: Thrust Bearing Removal/Installation
    GC0027459Courtesy of DAIMLERCHRYSLER CORP.
    1 - OUTPUT SHAFT
    2 - THRUST BEARING
  22. Remove the thrust bearing (2) from the main shaft (1). See Fig 21.
    Fig 22: Clutch Pressure Plate Removal/Installation
    GC0027460Courtesy of DAIMLERCHRYSLER CORP.
    1 - OUTPUT SHAFT
    2 - CLUTCH PRESSURE PLATE
  23. Remove the clutch pressure plate (2) from the main shaft (1) and clutch assembly. See Fig 22.
    Fig 23: Wavy Spring Assembly Removal/Installation
    GC0027461Courtesy of DAIMLERCHRYSLER CORP.
    1 - OUTPUT SHAFT
    2 - WAVY SPRING
  24. Remove the wave spring (2) from the main shaft (1). See Fig 23.
    Fig 24: Clutch Assembly Removal/Installation
    GC0027462Courtesy of DAIMLERCHRYSLER CORP.
    1 - OUTPUT SHAFT
    2 - CLUTCH ASSEMBLY
  25. Remove the clutch assembly (2) from the main shaft (1). See Fig 24.
    Fig 25: Front Drive Sprocket Retaining Ring Removal/Installation
    GC0027414Courtesy of DAIMLERCHRYSLER CORP.
    1 - FRONT OUTPUT SHAFT
    2 - RETAINING RING
  26. Remove the front drive sprocket retaining ring (2) from the front output shaft (1). See Fig 25.
    Fig 26: Front and Rear Drive Sprockets and Drive Chain Removal/Installation
    GC0027463Courtesy of DAIMLERCHRYSLER CORP.
    1 - FRONT DRIVE SPROCKET
    2 - MAINSHAFT DRIVE SPROCKET
    3 - DRIVE CHAIN
  27. Remove the front drive sprocket (1), mainshaft drive sprocket (2), and drive chain (3) as one. See Fig 26.
    Fig 27: Chain Guide Bolts Removal/Installation
    GC0027464Courtesy of DAIMLERCHRYSLER CORP.
    1 - CHAIN GUIDE RAIL
    2 - SCREWS
  28. Remove the screws (2) holding the chain guide rails (1) to the front housing. See Fig 27.
    Fig 28: Remove Chain Guide
    GC0027465Courtesy of DAIMLERCHRYSLER CORP.
    1 - DRIVE CHAIN GUIDE
  29. Remove the drive chain guides (1) from the transfer case. See Fig 28.
    Fig 29: Mainshaft and Differential Assembly Removal/Installation
    GC0027466Courtesy of DAIMLERCHRYSLER CORP.
    1 - MAINSHAFT AND DIFFERENTIAL ASSEMBLY
    2 - FRONT HOUSING
  30. Remove the mainshaft and differential assembly (1) from the front housing (2). See Fig 29.
    Fig 30: Removing/Installing Intermediate Clutch Shaft Snap Ring
    GC0006004Courtesy of DAIMLERCHRYSLER CORP.
    1 - SNAP-RING
    2 - INTERMEDIATE CLUTCH SHAFT
  31. Remove intermediate clutch shaft (2) snap-ring (1). See Fig 30.
    Fig 31: Remove/Install Intermediate Clutch Shaft Thrust Ring
    GC0006005Courtesy of DAIMLERCHRYSLER CORP.
    1 - CLUTCH SHAFT THRUST RING
  32. Remove the intermediate clutch shaft thrust ring (1). See Fig 31.
    Fig 32: Removing/Installing Intermediate Clutch Shaft
    GC0006006Courtesy of DAIMLERCHRYSLER CORP.
    1 - INTERMEDIATE CLUTCH SHAFT
  33. Remove the intermediate clutch shaft (1). See Fig 32.
    Fig 33: Removing/Installing Differential Snap Ring
    GC0006007Courtesy of DAIMLERCHRYSLER CORP.
    1 - DIFFERENTIAL SNAP-RING
  34. Remove the differential snap-ring (1). See Fig 33.
    Fig 34: Removing/Installing Differential
    GC0006008Courtesy of DAIMLERCHRYSLER CORP.
    1 - DIFFERENTIAL ASSEMBLY
    2 - MAINSHAFT
  35. Remove the differential assembly (1) from the mainshaft (2). See Fig 34.
    Fig 35: Removing/Installing Mode Hub and Retainer
    GC0006009Courtesy of DAIMLERCHRYSLER CORP.
    1 - DIFFERENTIAL ASSEMBLY
    2 - MODE HUB AND RETAINER
  36. Remove the mode hub (2) and mode hub retainer from the differential assembly (1). See Fig 35.
    Fig 36: Removing/Installing Retainer at Mode Hub
    GC0006010Courtesy of DAIMLERCHRYSLER CORP.
    1 - MODE HUB RETAINER
    2 - MODE HUB
  37. Remove the mode hub retainer (1) from the mode hub (2). See Fig 36.
    Fig 37: Range Fork and Sleeve Removal/Installation
    GC0027467Courtesy of DAIMLERCHRYSLER CORP.
    1 - RANGE FORK
    2 - RANGE HUB
  38. Remove the range fork and range hub as one. See Fig 37.
    Fig 38: Remove/Install Front Output Shaft Retaining Ring
    GC0027420Courtesy of DAIMLERCHRYSLER CORP.
    1 - FRONT OUTPUT SHAFT
    2 - RETAINING RING
  39. Remove the retaining ring (2) from the front output shaft (1). See Fig 38.
    Fig 39: Remove/Install Front Output Shaft and Flange
    GC0027421Courtesy of DAIMLERCHRYSLER CORP.
    1 - FRONT HOUSING
    2 - FRONT OUTPUT SHAFT
  40. Remove the front output shaft (2) from the front housing (1) and the front output shaft front bearing. See Fig 39.
    Fig 40: Oil Pump Pick-up Tube and Screen Removal/Installation
    GC0027469Courtesy of DAIMLERCHRYSLER CORP.
    1 - OIL PICK-UP TUBE AND SCREEN
  41. Remove the oil pick-up tube and screen (1) from the rear housing.
    Fig 41: Oil Pump Pick-up Tube O-ring Removal/Installation
    GC0027470Courtesy of DAIMLERCHRYSLER CORP.
    1 - REAR HOUSING
    2 - O-RING
  42. Remove the oil pick-up tube o-ring (2) from the rear housing (1). See Fig 41.
    Fig 42: Sector Shaft Retaining Ring Removal/Installation
    GC0027471Courtesy of DAIMLERCHRYSLER CORP.
    1 - SHIFT SECTOR
    2 - RETAINING RING
  43. Remove the retaining ring (2) from the shift sector shaft (1). See Fig 42.
    Fig 43: Sector Shaft Removal/Installation
    GC0027472Courtesy of DAIMLERCHRYSLER CORP.
    1 - FRONT HOUSING
    2 - SHIFT SECTOR
  44. Remove the shift sector (2) from the rear housing (1). See Fig 43.
    Fig 44: Removing/Installing Input Gear Retaining Ring
    GC0005865Courtesy of DAIMLERCHRYSLER CORP.
    1 - INPUT GEAR
    2 - RETAINING RING
  45. Remove the input shaft seal with a suitable pry tool or a screw mounted in a slide hammer.
  46. Remove the retaining ring (2) holding the input gear assembly into the front housing. See Fig 44.
    Fig 45: Input Planetary Assembly Removal/Installation
    GC0027468Courtesy of DAIMLERCHRYSLER CORP.
    1 - INPUT GEAR AND LOW RANGE PLANETARY
  47. Remove the input gear and low range planetary assembly (1) from the front housing. See Fig 45.
    Fig 46: Low Range Snap-ring Removal/Installation
    GC0027474Courtesy of DAIMLERCHRYSLER CORP.
    1 - INPUT GEAR
    2 - SNAP-RING
    3 - LOW RANGE PLANETARY
  48. Remove the snap-ring (2) holding the input gear (1) into the low range planetary (3). See Fig 46.
    Fig 47: Low Gear and Lock Plate Removal/Installation
    GC0027475Courtesy of DAIMLERCHRYSLER CORP.
    1 - INPUT GEAR
    2 - LOCK PLATE
    3 - LOW RANGE PLANETARY
  49. Remove the input gear (1) and lock plate (2) from the low range planetary (3) and remove the lock plate. See Fig 47.
    Fig 48: Top Thrust Washer Removal/Installation
    GC0027476Courtesy of DAIMLERCHRYSLER CORP.
    1 - INPUT GEAR
    2 - THRUST WASHER (NO TABS)
  50. Remove the top thrust washer (no tabs) (2) from the input gear (1). See Fig 48.
    Fig 49: Bottom Thrust Washer Removal/Installation
    GC0027477Courtesy of DAIMLERCHRYSLER CORP.
    1 - BOTTOM THRUST WASHER (3 TABS)
    2 - LOW RANGE PLANETARY
  51. Remove the bottom thrust washer (3 tabs) (1) from the low range planetary (2). See Fig 49.
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