For 1990-2009 cars

#### Tools Required

• | J 2619-01 Slide Hammer

• | J 8092 Driver Handle

• | J 9276-21 Slide Hammer Adapter

• | J 22912-01 Bearing Remover

• | J 29369 Output Shaft Bearing Remover

• | J 29369-2 Output Shaft Bearing Remover

• | J 33832 Bearing Installer/Remover

Important: The annulus gear found in this transfer case is not serviceable or removable. It should only be replaced as a unit with the front case half. If the annulus gear is removed, damage to the case will result.

1. Remove the oil pump from the pickup tube and the rear case half.
2. Remove the following components from the rear case half:

• | The oil pump pickup tube

• | The O-ring

• | The pump pickup filter

3. Remove the mode shift fork spring from the shift rail.
4. Remove the snap ring from the front output shaft.
5. Remove the following components from the mainshaft as an assembly:

(The mode shift fork and the shift rail will be removed with the mainshaft.)

• | The mainshaft

• | The drive chain

• | The driven sprocket

6. Remove the synchronizer from the mainshaft snap ring.
7. Remove the synchronizer assembly from the mainshaft.
8. Remove the drive sprocket from the mainshaft.
9. Remove the range shift fork and the range shift hub from the planetary carrier.
10. Remove the following components from the front case half:

• | The shift lever nut

• | The washer

• | The shift lever

• | The selector

• | The shaft assembly plastic washer

• | The O-ring seal

11. Remove the three bolts that secure the encoder motor to the front case.
12. Remove the input gear snap ring.
13. Remove the input bearing snap ring.
14. Use a soft faced hammer in order to remove the following components from the annulus gear:

• | The planetary carrier

• | The input gear

15. Remove the input gear to the planetary carrier assembly snap ring.
16. Remove the input gear from the planetary carrier.
17. Use the J 36370 and the J 8092 to remove the input bearing from the front case half.
18. Use the J 29369 , the J 9276-21 and theJ 2619-01 to remove the mainshaft pilot bearing from the input gear.
19. Remove the front output bearing snap ring.
20. Remove the front output shaft seal from the front case half.
21. Use the J 33832 and the J 8092 to remove the front output bearing from the front case half.
22. Remove the seal from the mainshaft extension housing
23. Remove the seal from the input bearing retainer.
24. Remove the front output rear bearing from the rear case half.
25. Remove the mainshaft bearing from the rear retainer housing.
26. Remove the magnet from the front case half.
27. Scribe the location of the synchronizer sleeve and the hub before disassembly.

This will aid in assembly.

28. Remove the main drive synchronizer stop ring from the synchronizer sleeve.
29. Remove the spring retainers from the synchronizer hub.

Important: Do not damage the synchronizer struts when removing the sleeve from the hub.

30. Remove the synchronizer hub from the synchronizer sleeve.

(The oil pump is not serviceable and should be replaced as a unit only.)