For 1990-2009 cars

### Disassembly Procedure

#### Tools Required

• | J 8092 Universal Driver Handle

• | J 36370 Drive Sprocket Needle Bearing Installer

• | J 29170 Drive Sprocket Bearing Remover

• | J 29369 Output Shaft Bearing Remover

• | J 9276-21 Adapter

• | J 2619-01 Slide Hammer

• | J 33790 Input Sungear Needle Bearing Installer

Important:

• | The annulus gear found in this transfer case is not serviceable or removed. The gear should only be replaced as a unit with the front case half. Damage will occur to the case if the gear is removed.

• | The oil pump is not a serviceable unit and should be replaced if it is defective.

1. Use solvent and a stiff brush to clean the exterior of the transfer case.
2. Remove the shift motor bolts.
3. Remove the shift motor.
4. Remove the vehicle speed sensor.
5. Remove the speed sensor O-ring from the sensor.
6. Remove the vacuum switch and its O-ring.
7. Remove the detent plug, spring, and plunger.
8. Remove the rear extension housing bolts.
9. Remove the rear extension housing. Tap the extension housing with a rubber hammer in order to free it from the sealer.
10. Remove the rear bearing retainer snap ring.
11. Remove the rear retainer housing bolts.

Important: Do not pry against the sealing surfaces.

12. Remove the rear retainer housing. Carefully pry upward under each tab on the retainer housing.
13. Remove the vehicle speed sensor rotor snap ring.
14. Remove the vehicle speed sensor rotor.
15. Remove the snap ring from the mainshaft.

Important: Some transfer case models have a bracket attached to them by the case bolts. These bolts are different from the others and must be returned into the correct holes.

16. Remove the case bolts. The two longer case bolts and washers go into the doweled holes.

Important: Damage may occur if you attempt to pry the case halves apart at any point on the mating surfaces.

17. Separate the case halves.

• | Insert screwdrivers into the slots that are molded into the case ends and pry apart.

• | Do not damage the oil pump on the rear case half.

18. Remove the oil pump.
19. Remove the oil pump pickup tube, O-ring, and pump pickup filter.
20. Remove the mode shift fork spring.
21. Remove the front output shaft seal.
22. Remove the front output shaft snap ring.
23. Remove the mainshaft, drive chain, and driven sprocket assembly. The mode shift fork and the shift rail will be removed with the mainshaft.
24. Remove the synchronizer to mainshaft snap ring.
25. Remove the synchronizer assembly.
26. Remove the drive sprocket.
27. Remove the shift fork and range shift hub. Rotate the sector shaft in order to obtain clearance for the range fork.
28. Remove the shift sector snap ring.
29. Remove the sector shaft assembly.
30. Remove the input bearing retainer bolts.
31. Remove the input bearing retainer.
32. Remove the input gear snap ring.
33. Use a soft face hammer in order to remove the input and low range gear assembly.
34. Remove the input gear to low range gear assembly snap ring.
35. Separate the input gear from the low range gear assembly.
36. Use the J 36370 and the J 8092 in order to remove the input bearing.
37. Use the J 29369 , the J 9276-21 , and the J 2619-01 in order to remove the needle bearings from the input gear.
38. Remove the front output bearing snap ring.
39. Use the J 33790 and the J 8092 in order to remove the front output bearing.
40. Remove the seal from the mainshaft extension housing.
41. Remove the input bearing retainer seal.
42. Use the J 2619-01 and the J 29369-2 in order to remove the front output rear bearing.
43. Use the J 33790 in order to remove the mainshaft bearing from the oil pump retainer.
44. Remove the magnet from the front case.
45. Disassemble the main drive synchronizer stop rings from the synchronizer sleeve.

• | Mark the location of the synchronizer hub and sleeve.

• | The synchronizer teeth must align with the struts.

46. Remove the spring retainers from the synchronizer hub.
47. Separate the synchronizer hub from the synchronizer.
48. Remove the oil pump screws from the oil pump.