Tools Required

Important: Because of manufacturing design changes made during this model year, the transfer case was manufactured with either a 1st design rear output shaft and clutch hub or a 2nd design rear output shaft and clutch hub. The 1st design is a loose fit assembly; the clutch hub splines have a clearance fit to the rear output shaft splines and can be assembled or disassembled by hand. The 2nd design is a press fit assembly; the clutch hub splines have an interference fit to the rear output shaft splines and must be assembled or disassembled using a hydraulic press. The components can be identified by the following:

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 fill plug (1) and the drain plug (2) and drain the transfer case fluid.



5. Remove the connector, for the actuator encoder motor wiring harness, from the bracket.
6. Remove the actuator encoder motor mounting bolts.
7. Remove the actuator encoder motor assembly.
8. Remove the actuator insulator gasket.



9. Remove the plastic vent from the case; a NEW aluminum vent must be installed during assembly.



10. Remove the rear vehicle speed sensors (VSS).



11. Remove the front VSS.



12. Remove the access hole plug.




Notice: Do not damage the sealing surfaces of the transfer cases or the shafts when prying the seals for removal. Damaging the sealing surface may cause leakage or require replacement of the damaged component.

13. Remove the input shaft seal by prying it out of the front case.



14. Remove the rear output shaft seal.



15. Inspect the rear output shaft bushing for scoring or wear.
16. Remove the rear output shaft bushing using the J 45380 .

16.1.

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

16.2.

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

16.3.

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





Important: 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.

17. Remove the transfer case retaining bolts and washers.

Mark the location of any brackets.





Notice:  Do not nick, scratch or damage the sealing surface. The sealing surface is a machined surface. Damage to the machined surface can cause leakage.

18. Insert a flat-blade screwdriver into the slot on the left side of the transfer case.



19. Insert a flat-blade screwdriver into the slot on the right side of the transfer case.
20. With equal pressure, press down on the screwdrivers in order to separate the front case half and the rear case half.



21. Insert a pair of snap ring pliers and release the outer retaining ring for the rear output shaft bearing.



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



23. Remove the oil pump wear sleeve, a new wear sleeve is required.



24. Remove the rear output shaft rear bearing retaining ring.



25. Remove the rear output shaft rear bearing.



26. Remove the rear output shaft speed sensor reluctor wheel.



27. Remove the oil pump suction pipe assembly. Do not remove the screen from the pipe.



28. Remove the magnet.



29. Remove the oil pump wave spring.
30. Remove the oil pump assembly.



31. Remove the oil pump suction pipe O-ring from the oil pump.



32. Remove the drive sprocket retaining ring.



33. Remove the driven sprocket retaining ring.




Important: If the chain and sprockets are to be used again, mark the relationship of the chain to the sprockets in order to mark the wear patterns.

34. Remove the chain and sprockets.
35. Remove the chain from the drive sprocket and driven sprocket.



36. Remove the rear output shaft assembly.
37. Mount the rear output shaft assembly, with the input end up, in a soft-jaw vise.



38. Remove the clutch assembly retaining ring. Push down on the clutch apply plate to access the retaining ring.



39. Remove the clutch apply plate assembly.
40. Remove the clutch return spring.



41. Remove the clutch apply plate bearing and inner support from the clutch apply plate.



42. Inspect the bearing for being faulty. Refer to Transfer Case Cleaning and Inspection .
43. If the bearing is faulty, using a hydraulic press and a suitable adapter, remove the clutch apply plate bearing from the clutch bearing inner support.
44. Discard the bearing after removal.



45. Remove the clutch hub retaining ring.
46. If 1st design, remove the clutch housing and hub assembly from the rear output shaft.




Important: Do not press against the outer portion of the clutch housing (2).

47. If 2nd design, reinstall the drive sprocket (3) to the clutch housing (2). The drive sprocket (3) will be used to press against.
48. If 2nd design, place the rear output shaft assembly into a hydraulic press with the input end facing up and the drive sprocket (3) supporting the assembly against the hydraulic press blocks (4).

Important: A maximum of 3 200 kg (7,055 lb) may be necessary to remove the rear output shaft (1) from the clutch hub.

49. If 2nd design, press the rear output shaft (1) from the clutch hub.



50. Turn the clutch assembly over on a workbench.
51. Remove the clutch housing.

Important: Do not remove the oil restrictor plate. The oil restrictor plate is only serviced with the clutch hub.

52. Remove the clutch hub.




Important: Do not wash the clutch inner friction plates in cleaning solvent.

53. Separate the clutch plates for inspection.
54. Remove and discard the shim or shims.



55. Remove the oil restrictor from the rear output shaft, if replacing the shaft.



56. Inspect the bearing in the clutch housing for being faulty. Refer to Transfer Case Cleaning and Inspection .
57. If the bearing is faulty, use a brass drift and a hammer to remove the bearing.



58. Remove both of the clutch lever pivot pins with the aluminum washers and the O-ring seals.



59. Remove the clutch lever assembly from the control actuator lever.



60. Remove the shift fork shaft.



61. Remove the range shift fork and the range shift sleeve as an assembly.

It may be necessary to lightly pry the roller on the shift fork from the control actuator lever.




62. Remove the range shift sleeve from the range shift fork.



63. Remove the input gear bearing outer retaining ring.




Important: Depending on the version of the transfer case, it may have either a 3 pinion gear or 6 pinion gear planetary carrier assembly. The 3 pinion gear planetary carrier is used with transmission RPO M30 and the input gear splines are 27 teeth. The 6 pinion gear planetary carrier is used with transmission RPO MT1 and MN8 and the input gear splines are 32 teeth. The repair procedures are the same for both planetary carriers.

64. Remove the high/low planetary carrier.



65. Remove the planetary gear shaft retaining ring.



66. Remove the planetary carrier lock ring.



67. Remove the input gear front thrust washer.



68. Remove the input gear from the planetary carrier.



69. Remove the input gear rear thrust washer.



70. Inspect the pilot bearing in the input gear for being faulty. Refer to Transfer Case Cleaning and Inspection .
71. Remove the pilot bearing from the input gear using a brass drift and a hammer.



72. Remove the inner retaining ring for the front output shaft bearing.



73. Using a soft-face hammer, remove the front output shaft, with the bearing, from the front case half.



74. Using a suitable punch, remove the front output shaft seal from the front case half.



75. Remove the outer retaining ring for the front output shaft bearing.



76. Inspect the front output shaft bearing for being faulty. Refer to Transfer Case Cleaning and Inspection .
77. Remove the bearing from the front output shaft. Do not use the bearing again after removal.



78. If damaged, remove the speed sensor reluctor wheel from the front output shaft, using a hydraulic press. Do not use the speed sensor reluctor wheel again after removal.



79. If the cup plug in the front output shaft is leaking, remove the plug using a brass drift.



80. Remove the input bearing retaining ring.



81. Remove the input bearing.



82. Inspect the front output shaft rear bearing for being faulty. Refer to Transfer Case Cleaning and Inspection .
83. If the bearing is faulty, remove the bearing using the J 23907  (2) and the J 26941  (1).



84. Remove the control actuator lever shaft retaining ring.



85. Remove the control actuator lever shaft.
86. Inspect the control actuator lever bearing and seal for being faulty. Refer to Transfer Case Cleaning and Inspection .
87. If the bearing is leaking or faulty, remove the bearing from the case.