Disassembly And Assembly

DISASSEMBLY

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1 - MAINSHAFT

11 - THRUST WASHER

2 - DRIVE SPROCKET

12 - THRUST BEARING

3 - CLUTCH HOUSING

13 - BALL RAMP A LEVER

4 - CLUTCH HOUSING RETAINING RING

14 - BALL

5 - SPROCKET SPACER T-WASHER

15 - LEVER B ASSEMBLY

6 - CLUTCH HUB

16 - THRUST BEARING

7 - FRICTION PLATE

17 - THRUST WASHER

8 - STEEL REACTION PLATE

18 - THRUST COLLAR

9 - CLUTCH SPRING

19 - CLUTCH SHIM

10 - CLUTCH PISTON

20 - RETAINING RING

NOTE:

If the transfer case assembly is being reconditioned (clutch/seal replacement) or replaced, it is necessary to perform the Quick Learn Procedure using the Scan Tool.

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Remove the clutch upper snap ring.

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Remove the clutch shim.

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Remove the thrust collar.

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Remove the upper thrust bearing race.

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Remove the upper thrust bearing.

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Remove the upper shift lever.

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Remove the shift lever balls.

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Remove the lower shift lever.

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Remove the lower thrust bearing.

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Remove the lower bearing race.

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Remove the clutch apply piston.
NOTE:
For ease of installation note the assembly orientation of the 4 identical springs.

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Remove the clutch return springs.
NOTE:
For ease of installation note the assembly configuration of the clutch plates and friction discs.

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Remove the clutch pack.

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Remove the inner clutch hub.

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Remove the clutch hub thrust washer (1) and snap ring (2).

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Remove the outer clutch drum from the main shaft and drive sprocket.

ASSEMBLY

NOTE:

If the transfer case assembly is being reconditioned (clutch/seal replacement) or replaced, it is necessary to perform the Quick Learn Procedure using the Scan Tool.

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Install the outer clutch drum onto the main shaft and drive sprocket.

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Install the clutch hub snap ring (2) and thrust washer (1).

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Install the inner clutch hub.

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Starting with friction disc and ending with a friction disc, install the clutch pack.
NOTE:
The four identical springs must be installed in the orientation shown.

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Install the clutch return springs.

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Install the clutch apply piston with the lettering up and the stepped face down.

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Install the lower thrust bearing race.

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Install the lower thrust bearing.

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Install the lower shift lever.

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Install the shift lever balls into their pockets.

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Install the upper shift lever.

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Install the upper thrust bearing.

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Install the upper thrust bearing race.

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Install the thrust collar.

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Install the clutch shim.

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Install the clutch upper snap ring.