For 1990-2009 cars

• | J 3289-20 Holding Fixture

• | J 23907 Slide Hammer with Bearing Adapter

• | J 26941 Bushing and Bearing Remover - 3-4 in

• | 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. 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 and fill plugs.
5. Drain the fluid from the transfer case.
6. Remove the encoder motor mounting bolts.
7. Remove the encoder motor assembly.
8. Remove the encoder motor gasket.
9. Remove the left rear speed sensor.
10. Remove the right rear speed sensor.
11. Remove the front speed sensor.
12. Remove the vent tube, only if it is damaged.
13. Remove the rubber plug.

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

14. Remove the front output shaft seal.

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

15. Remove the input shaft seal.

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

16. Remove the rear output shaft seal.
17. Inspect the rear bushing for scoring or wear.
18. Using the J 45380 , remove the rear 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 bushing.

19. Remove the transfer case retaining bolts and studs.
20. Mark the location of the studs and brackets.
21. Insert a flat bladed screwdriver in the slot on the left side of the transfer case.
22. Insert a flat bladed screwdriver in the slot on the right side of the transfer case.
23. Apply equal pressure on both of the screwdrivers, in a downward motion, and separate the front and rear case halves.
24. Insert snap ring pliers in the slot.
25. Using the snap ring pliers, open the retaining ring for the rear output shaft bearing.
26. Remove the rear case from the front case.
27. Remove the oil pump wear sleeve, only if it is worn or damaged.
28. Remove the rear output shaft bearing retaining ring.
29. Remove the rear output shaft bearing.
30. Remove the speed reluctor wheel.

Important: The rear output shaft may be an original design (2) or the replacement design (1). The original design rear output shaft (2) uses an oil pump wave washer above the oil pump and a retaining ring under the oil pump. The original design rear output shaft (2) is identified by the splines in the area by the oil gallery hole. The replacement design rear output shaft has a smooth area by the oil gallery hole.

31. Inspect the rear output shaft to identify as an original design (2) or the replacement design (1).
32. Remove the oil pump wave spring, if original design rear output shaft.
33. Remove the magnet.
34. Remove the oil pump screen assembly.
35. Remove the oil pump assembly.
36. Remove the oil pump pick up tube seal.
37. Remove the oil pump retaining ring, if original design rear output shaft.
38. Remove the drive sprocket retaining ring.
39. Remove the driven sprocket retaining ring.

Important: If the drive chain and sprockets are to be used again, mark the relationship of the drive chain to the sprockets for proper alignment of the wear pattern.

40. Remove the drive chain and sprockets.
41. Remove the rear output shaft assembly.
42. Mount the rear output shaft in a soft-jaw vise with the input end up.
43. Remove the clutch retaining ring.
44. Remove the clutch pressure plate assembly.
45. Remove the clutch pressure plate bearing along with the clutch pressure plate hub, from the clutch pressure plate.
46. Inspect the bearing for being faulty. Refer to Transfer Case Cleaning and Inspection .
47. If the bearing is faulty, using a hydraulic press and a suitable adapter, remove the clutch pressure plate bearing from the clutch pressure plate hub.
48. Discard the bearing after removal.
49. Remove the clutch hub retaining ring.
50. Remove the clutch housing and hub assembly from the rear output shaft.
51. Remove the clutch spring.
52. Turn the clutch assembly over on a workbench.
53. Remove the clutch housing.
54. Remove the clutch hub.
55. Remove the clutch backing plate.

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

56. Separate the clutch plates for inspection.
57. Remove and discard the shim or shims.
58. Remove the oil restrictor from the rear output shaft, if replacing the shaft.
59. Inspect the bearing in the clutch housing for being faulty. Refer to Transfer Case Cleaning and Inspection .
60. If the bearing is faulty, use a brass drift and a hammer to remove the bearing.
61. Remove both of the clutch lever pivot pins with washers and O-ring seals.
62. Remove the shift detent spring bolt.
63. Remove the following components:

• | The shift detent plunger plug O-ring seal

• | The shift detent spring

• | The shift detent plunger

64. Remove the clutch lever assembly.

Important: Do not scratch the oil seal surface of the input shaft with the retaining ring.

65. Remove the input shaft retaining ring.
66. Remove the input shaft bearing retaining ring.
67. Remove the input shaft assembly.
68. Remove the input shaft bearing. Do not use the bearing again after removal.
69. Using a brass drift, remove the input gear pilot bearing. Do not use the bearing again after removal.
70. Remove the front output shaft dust shield.

Important: Do not scratch the oil seal surface on the front output shaft when removing the retaining ring.

71. Remove the front output shaft retaining ring.
72. Remove the front output shaft assembly.
73. 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.
74. Remove the front output shaft bearing retaining ring.
75. Remove the front output shaft bearing.
76. Remove the mounting studs, only if they are damaged.
77. Inspect the front output shaft rear bearing for being faulty. Refer to Transfer Case Cleaning and Inspection .
78. If the bearing is faulty, remove the bearing using the J 23907 (2) and the J 26941 (1).
79. Remove the retaining ring for the control actuator lever shaft.
80. Remove the control actuator lever shaft.
81. Inspect the control actuator lever bearing and seal for being faulty. Refer to Transfer Case Cleaning and Inspection .
82. If the bearing is leaking or faulty, remove the bearing from the case.