Transfer Case Disassemble

Tools Required 

• J 2619-01  Slide Hammer
• J 5590  Crankshaft Sprocket Installer
• J 22912-01  Split Plate Bearing Puller
• J 44380  Bearing Race Remover
• J 44737  Bearing Remover
• J 44754  Bearing Remover
• J 44755  Holding Fixture

1. Remove the drain plug (1) from the extension housing. Allow the gear oil to drain.
   Fig 1: Locating Extension Housing Drain & Fill Plugs

   
2. Remove the drain plug (1) from the case-left. Allow the transmission oil to drain.
   Fig 2: Locating Case-Left Drain Plug

   
3. Install the transfer case assembly (1) onto the J 44755  (3). Position the carrier onto the post of the fixture.
4. Install the retaining bolts (2).

   Tighten 

   Tighten the bolts to 50 N.m (37 ft lbs).

   Fig 3: Installing Transfer Case Assembly Onto Holding Fixture

   
5. Remove the hose and clamp assembly (1), vent hose (2), and bolt (3).
   Fig 4: Removing Vent Hose Assembly

   
6. Remove the speed sensor (1).
   Fig 5: Removing Speed Sensor

   
7. Remove the O-ring seal from the sensor, if required. The O-ring seal may be reused if not cut or damaged.
8. Remove the extension housing assembly (1), bolts (3), and shim (2). Mark or tag the shim for assembly.
   Fig 6: Removing Extension Housing Assembly

   
9. If reusing the drivenshaft bearings, measure in both directions, the rotating torque of the drivenshaft and record the value for assembly.
   Fig 7: Measuring Rotating Torque Of Drivenshaft

   
10. Install the extension housing assembly (3) and the M8 x 1.25 bolts (1) to the J 44755  (2).

    Tighten 

    Tighten the bolts to 25 N.m (18 ft lbs).

    Fig 8: Installing Extension Housing Assembly Onto Holding Fixture

    
11. Remove the nut (1).
12. Remove the extension housing assembly and bolts from J 44755. 
    Fig 9: Removing Extension Housing Flange Nut

    
13. Position the extension housing assembly into a press.
    Fig 10: Positioning Extension Housing Assembly Into Press

    
14. Remove the flange (1), spacer (5), and shaft (9) from the housing (6). Discard the spacer (5).
15. Remove the oil seal (2) and bearing (3).
    Fig 11: Disassembling Extension Housing Assembly

    
16. Use the J 44380  (2) and the J 2619-01  (1) in order to remove the bearing races from the housing (3), if required.
    Fig 12: Removing Bearing Races From Extension Housing

    
17. Install J 22912-01  (1) or equivalent onto the shaft.
18. Position the shaft into a press.
19. Remove the bearing from the shaft.
    Fig 13: Removing Bearing From Output Drivenshaft

    
20. Remove the bolts (1 and 5), housing (2), shim (3), and O-ring seal (4) from the case-left. Mark or tag the shim for assembly.
    Fig 14: Removing Output Driveshaft Housing

    
21. Remove the bolts (1) from the case.
    Fig 15: Removing Case Bolts

    

    Important:  When separating the case halves, avoid damage to the seating surfaces. Do not insert a screwdriver or prying tool between the case sealing surfaces.

22. Rotate the J 44755  90 degrees.
23. Separate the case-right (2) from the case-left (1).
    Fig 16: Separating Case-Right From Case-Left

    
24. Remove the idler gear (1) from the case-right.
    Fig 17: Removing Idler Gear

    
25. Note the installed position of the idler gear. The side of the gear with the longer flange area (1) is to be installed to the case-right.
    Fig 18: Identifying Installed Position Of Idler Gear

    
26. Install the J 22912-01  (1) onto the gear.
27. Position the gear into a press.
    Fig 19: Installing Split-Plate Bearing Puller Onto Idler Gear

    
28. Remove the bearings (1 and 3) from the gear (2).
    Fig 20: Removing Bearings From Idler Gear

    
29. Install the case-left (2) onto the J 44755  (1). Align the notched area of the tool with the flat areas of the driveshaft.
    Fig 21: Installing Left Case Onto Holding Fixture

    
30. Remove the nut (1) from the driveshaft.
    Fig 22: Removing Driveshaft Nut

    
31. Position the case-left into a press.
    Fig 23: Positioning Left Case Into Press

    
32. Remove the gear (8), bearing (7), shim (5), and shaft (1) from the case-left. Mark or tag the shim for assembly.
    Fig 24: Disassembling Left Case

    
33. Use the J 44380  (2) and the J 2619-01  (1) in order to remove the bearing races from the case-left (3).
    Fig 25: Removing Bearing Races From Left Case

    
34. Remove the oil seals (4) from the case-left.
    Fig 26: Removing Oil Seals From Left Case

    
35. Install the J 22912-01  (1) or equivalent onto the shaft.
36. Position the shaft into a press.
37. Remove the bearing from the shaft.
    Fig 27: Removing Bearing From Output Driveshaft

    
38. Install J 44380  (2) into the case-left idler gear bearing race.
39. Install J 2619-01  (1) to J 44380  (2).
    Fig 28: Installing Bearing Race Remover/Slide Hammer

    
40. Remove the idler gear bearing race (1) from the case-left.
    Fig 29: Removing Idler Gear Bearing Race From Left Case

    
41. Install the case-right (1) onto the J 44755  (2). Position the carrier onto the post of the fixture.
    Fig 30: Installing Right Case Onto Holding Fixture

    
42. Remove the oil seal (1) from the case-right.
    Fig 31: Removing Oil Seal From Right Case

    
43. Remove the nut (1) from the carrier.
    Fig 32: Removing Differential Carrier Nut

    
44. Position the case-right into a press.
45. Install the J 5590  (1) to the differential carrier.
    Fig 33: Installing Crankshaft Sprocket Installer To Differential Carrier

    
46. Remove the bearing (2), shim (6) and differential carrier (8) from the case-right (4). Mark or tag the shim for assembly.
    Fig 34: Removing Differential Carrier & Related Components

    
47. Use the J 44380  (2) and the J 2619-01  (1) in order to remove the bearing races from the case-right (3), if required.
    Fig 35: Removing Bearing Races From Right Case

    
48. Install the J 44754  (1) over the differential carrier bearing.
    Fig 36: Installing Bearing Remover Onto Differential Carrier

    
49. Install the J 22912-01  (3) over the J 44754  (2). Tighten until snug.
50. Position the carrier and J 5590  (1) into a press in order to remove the bearing.
    Fig 37: Positioning Carrier & Crankshaft Sprocket Installer Into Press To Remove Bearing

    
51. Install the J 44380  (2) into the case-right idler gear bearing race.
52. Install J 2619-01  (1) to J 44380  (2).
    Fig 38: Installing Bearing Race Remover/Slide Hammer

    
53. Remove the bearing race (1) and shim (2). Mark or tag the shim for assembly.
    Fig 39: Removing Bearing Race & Shim

    
54. Install the J 44737  (2) into the driveshaft bearing. Tighten the tool until snug.
55. Install the J 2619-01  (1) to the J 44737  (2).
    Fig 40: Installing Bearing Remover/Slide Hammer

    
56. Remove the bearing (3) from the case-right.
    Fig 41: Removing bearing from right case

    
57. Remove the roll pin (2) and shaft (1) from the differential carrier, if required.
    Fig 42: Removing Roll Pin & Shaft From Differential Carrier

    
58. Remove the side gears (2), pinion gears (3), and washers (1 and 4) from the carrier, if required.
    Fig 43: Removing Side Gears, Pinion Gears & Washers From Carrier

    
59. Remove the ring (10) from the carrier, if required.
60. Remove the pin (9), gear (3) and washers (1, 2, 7, and 8) from the carrier, if required.
61. Remove the needle bearings (4 and 6) and washer (5) from the gear (3), if required.
    Fig 44: Disassembling Carrier