For 1990-2009 cars

#### Tools Required

• | J 3289-20 Holding Fixture

• | J 8092 Universal Driver Handle

• | J 22912-B Split Plate Bearing Puller

• | J 23907 Slide Hammer with Bearing Adapter

• | J 29369-1 Bushing and Bearing Remover

• | J 33790 Bearing Remover

• | J 45380 Transfer Case Rear Bushing Remover and Installer

• | J 45759 Assembly Fixture

1. Attach the J 45759 to the transfer case using the adapter studs or bolts. 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 a pivot pin.

Important: If a bearing is found to be defective, it is not recommended that the bearing be replaced separately. The bearing may only be available in a subassembly.

4. Remove the speed sensor.
5. Remove the encoder motor mounting bolts.
6. Remove the encoder motor assembly.
7. Remove the detent assembly.
8. Remove the first front output shaft retaining ring.
9. Remove the front output shaft rubber washer.
10. Remove the front output shaft seal.
11. Remove the second front output shaft retaining ring.
12. Inspect the rear output shaft bushing for scoring or wear.
13. Remove the rear output shaft bushing using the J 45380 .

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

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

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

14. Remove the rear extension housing mounting bolts.
15. Remove the rear extension housing.
16. Remove the rear output shaft retaining ring.
17. Remove the rear output shaft bearing housing mounting bolts.
18. Remove the rear output shaft bearing housing.
19. Remove the first tone wheel retaining ring.
20. Remove the tone wheel.
21. Remove the second tone wheel retaining ring.
22. Remove the transfer case retaining bolts.
23. Remove the rear case half from the front case half.
24. Remove the oil pump pick-up assembly.
25. Remove the oil pump assembly.

Important:

• | If the drive chain is to be used again, mark the relationship of the drive chain to the sprockets. This will ensure that the wear pattern on the drive chain and the drive sprockets will be matched during assembly.

• | The drive sprocket is part of the synchronizer assembly and can only be removed from the front of the rear output shaft.

• | The driven sprocket is part of the front output shaft and not a separate part.

26. Remove the drive chain and the front output shaft.
27. Remove the mode fork retaining spring assembly.

Important: When performing the following service procedure, remove the rear output shaft and the mode fork as an assembly.

28. Remove the rear output shaft assembly.
29. Remove the mode fork from the rear output shaft.
30. Remove the low range fork assembly.
31. Remove the range shift sleeve.
32. Remove the sector shaft retaining ring.
33. Remove the sector shaft plastic sleeve.
34. Remove the sector shaft O-ring.
35. Remove the sector shaft.
36. Remove the input shaft bearing retainer mounting bolts.
37. Remove the input shaft retaining ring.
38. Using the J 22912-B , remove the input shaft bearing.
39. Remove the planetary gear assembly.

Important: It is not necessary to break down the synchronizer assembly into individual pieces. If any part of the synchronizer assembly is found to be excessively worn or damaged, replace the synchronizer as an assembly.

40. Remove the synchronizer assembly retaining ring.
41. Remove the synchronizer assembly.
42. Remove the synchronizer ring.
43. Remove the drive sprocket.
44. Remove the input gear retaining ring.
45. Remove the thrust plate from the planetary gear.
46. Remove the thrust washer from the planetary gear.
47. Remove the input gear.
48. Remove the thrust washer.
49. Remove the input seal.
50. Remove the output shaft seal.
51. Using the J 29369 and the J 23907 , remove the input gear pilot bearing.
52. Remove the front output shaft retaining ring.
53. Using the J 33790 and the J 8092 , remove the front output shaft front bearing from the from case.
54. Using the J 33790 and the J 8092 , remove the output shaft rear bearing from the retainer.
55. Using the J 33790 and the J 8092 , remove the front input shaft bearing.