IV. TRANSFER CASE DISASSEMBLY
Important: Read this section before starting the disassembly procedures.
General Precautions for Disassembly
After removing the transfer case from the vehicle,
remove any mounting brackets still attached to the
The outside of the unit should be cleaned before
starting the disassembly. If steam cleaning, ensure
that breather and air fittings are covered to prevent
water from entering assembly.
Assemblies - When disassembling the various
assemblies, lay all parts on a clean bench in the
same sequence as removed. This procedure will
simplify reassembly and reduce the possibility of lost
When necessary to apply a force to remove a part,
use of a puller or press would be preferred.
However, sometimes it may be necessary to use a
soft hammer or mallet.
Cleanliness provide a clean place to work. It is
important that no dirt or foreign material enters the
unit during repairs.
Position the transfer case horizontally, with the cover
plate facing upwards. A specially fabricated stand is
Bearings Carefully wash and relubricate all bearings
as removed and protectively wrap until ready for use.
Remove bearings with pullers designed for this
purpose, or in a manner which will not damage those
bearings that will be reused.
Follow each procedure closely in each section,
making use of both text and pictures. Refer to
exploded views located in Section VIII.
Preparation for Disassembly
Remove locknut and washer from each yoke or
companion flange on the upper and lower shafts.
Remove each companion flange or yoke from its
shaft. A gear puller may be required for yoke or
flange removal. Discard the used locknuts and
replace with new nuts at assembly.
Remove bolts and lockwashers from cover plate.
Tap cover plate to loosen and remove.
Remove hand brake assembly from lower shaft if
case is so equipped.