Tools Required

1. Attach the J 45759 to the transfer case using the adapter studs. All of the transfer case disassembly procedures can be performed with the case mounted to the J 45759 .



2. Mount the J 3289-20  (1) to a sturdy workbench.
3. Install the J 45759  (2) into J 3289-20  (1) and secure with pivot pin.



4. Remove the drain plug (2) and the fill plug (1).
5. Drain the fluid from the transfer case.



6. Remove the access plug from the transfer case.



7. Remove the transfer case vehicle speed sensor.
8. Remove the plastic vent from the case; a NEW aluminum vent must be installed during assembly.

Notice: Refer to Transfer Case Seal Removal Notice in the Preface section.




9. Remove the input shaft seal.



10. Remove the rear output shaft seal.



11. Inspect the rear output shaft bushing for scoring or wear.
12. Using the J 45380 , remove the rear output shaft bushing.

•	Install the finger section of the J 45380 in front of the bushing.

•	Install the tube and forcing screw assembly to the finger section. Ensure the forcing screw is backed out.

•	Using a wrench on the forcing screw, remove the rear output shaft bushing.

Notice: Refer to Transfer Case Seal Removal Notice in the Preface section.





Important: The front output shaft seal is a two piece internal style seal. The inner seal race is a force fit on the front output shaft.

13. Remove the front output shaft seal by inserting a flat-tip screwdriver in the inner seal race.
14. Pry the inner seal race forward.



15. Using a small pry bar, move the inner seal race forward on the front output shaft.
16. Remove the inner seal race from the front output shaft.



17. Insert a flat-tip screwdriver or a small pry bar between the outer lip of the front output shaft seal and the transfer case.



18. Remove the remaining part of the front output shaft seal from the transfer case.




Important: 

•	Mark the location of the brackets.

•	The magnesium transfer cases are using new style bolts that have a cup style washer. The cup washer is only available with the bolt. If the cup washer is not damaged, the bolt can be used again.

19. Remove the transfer case bolts, washers, and brackets.



20. Insert a flat-blade screwdriver in the slot on the left side of the transfer case.



21. Insert a flat-blade screwdriver in the slot on the right side if the transfer case.
22. With equal pressure, press down on the screwdrivers.



23. Insert a pair of snap ring pliers into the slot.
24. Using the snap ring pliers, open the outer rear output shaft bearing retaining ring.



25. Remove the rear case half from the front case half.



26. Remove the oil pump screen assembly.



27. Remove the rear output shaft assembly. Hold the planetary carrier in place to prevent removing it with the rear output shaft.



28. Remove the rear output shaft bearing retaining ring.



29. Using the flat side of the J 22912-B and a press, remove the rear output shaft bearing.




Important: Move the oil pump retaining ring down and away from the tone wheel. This ensures that the J 22912-B does not get caught on the retaining ring.

30. Using the J 22912-B and a press, remove the speed reluctor wheel.
31. Discard the speed reluctor wheel after removal.



32. Remove the oil pump retaining ring.



33. Remove the oil pump assembly.



34. Using a flat-blade screwdriver, unseat the annulus retaining ring.



35. Remove the annulus gear retaining ring.



36. Remove the rear output shaft.



37. Inspect the mainshaft rear bushing in the rear output shaft for being faulty. Refer to Transfer Case Cleaning and Inspection .
38. Using the J 2619-01  (1) and the J 45548  (2), remove the mainshaft rear bushing.



39. Remove the planetary carrier assembly. Tap on the end of the mainshaft with a soft-face hammer while lifting off the planetary carrier. A spring style retaining ring holds the planetary carrier to the mainshaft.



40. Remove the planetary carrier assembly thrust washer.



41. Remove the sun gear.



42. Remove the carrier retaining ring.



43. Remove the mainshaft.



44. Remove the planetary carrier sun gear bearing.



45. Remove the driven sprocket retaining ring.



46. Remove the drive chain assembly.



47. Remove the viscous coupling.



48. Using a flat-blade screwdriver, remove the input gear bearing retaining ring from the groove.



49. Remove the input gear bearing retaining ring.



50. Remove the input gear assembly.



51. Remove the input gear bearing retaining ring.



52. Using a press, remove the input bearing.



53. Remove the front output shaft bearing retaining ring.



54. Remove the front output shaft assembly.



55. Remove the front output shaft bearing retainer ring.



56. Remove the front output shaft bearing.



57. Inspect the front output shaft rear bearing. Refer to Transfer Case Cleaning and Inspection .
58. Using the J 23907  (2) and the J 26941  (1), remove the front output shaft bearing from the rear case.