For 1990-2009 cars

#### Tools Required

• | J 2619-01 Slide Hammer

• | J 8092 Driver Handle

• | J 22912-01 Bearing Remover

• | J 29369 Output Shaft Bearing Remover

• | J 29369-2 Output Shaft Bearing Remover

• | J 9276-21 Slide Hammer

• | J 33832 Bearing Installer/Remover

Important: The annulus case found in this transfer case is not serviceable or removable. The annulus case should only be replaced as a unit with a front case half. If the annulus case 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 oil tube connector

• | The pump pickup screen

3. Remove the mode fork shift spring from the shift rail.
4. Remove the snap ring from the front output shaft.
5. Remove the following components from the front case half 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

• | Note the location of the drive chain master link.

6. Remove the synchronizer to the mainshaft snap ring.
7. Remove the synchronizer assembly from the mainshaft.
8. Remove the drive sprocket from the mainshaft.
9. Rotate the selector with the shaft in order to obtain clearance when removing the range fork.

Remove the range shift fork and the range shift hub and the shaft from the planetary carrier.

10. Remove the following components from the front case half:

10.1. | The shift lever nut

10.2. | The washer

10.3. | The shift lever

10.4. | The selector

10.5. | The shaft assembly

10.6. | The plastic washer

10.7. | The O-ring seal

11. Remove the following components from the front case half:

11.1. | The input bearing retainer bolts

11.2. | The input bearing retainer

12. Remove the input bearing snap ring.
13. Use a soft faced hammer to remove the following components from the annulus gear:

13.1. | The planetary carrier

13.2. | The input gear

14. Remove the input gear to the planetary carrier assembly snap ring.
15. Remove the input gear from the planetary carrier.
16. Use the J 36370 and the J 8092 to remove the input bearing from the front case half.
17. Inspect the needle bearing in the input shaft. Replace the needle if the needle is damaged.
18. Use the J 29369 , the J 9276-21 , and the J 2619-01 in order 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 8092 and the J 33832 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. Insert the J 29369-2 behind the front output needle bearing.
25. Use the J 2619-01 in order to drive the bearing from the rear case half.
26. Remove the mainshaft bearing from the rear retainer housing.
27. Remove the magnet from the front case half.
28. Scribe the location of the synchronizer sleeve and the hub in order to aid in assembly.
29. Remove the main drive synchronizer stop ring from the synchronizer sleeve.
30. Remove the 2 spring retainers from the synchronizer hub.

Important:

• | Do not damage the synchronizer struts when removing the sleeve from the hub.

• | The oil pump is not serviceable. The oil pump should be replaced as a unit only.

31. Remove the synchronizer hub from the synchronizer sleeve.