Page 2249 of 2627
(8) Remove rear extension housing (Fig. 6). Tap
extension once or twice with a plastic mallet to break
sealer bead and loosen it.
OIL PUMP AND REAR CASE
(1) Disengage the oil pump pick-up tube (Fig. 7)
from the oil pump.
NOTE: The oil pump pick-up tube seals to the oil
pump with an o-ring. Verify that the o-ring was
removed with the tube and is in good condition.
Replace the o-ring if necessary.(2) Remove the oil pump (Fig. 8).
(3) Remove rear case-to-front case bolts (Fig. 9).
Fig. 7 Disengage The Oil Pick-up From Oil Pump
1 - OIL PUMP
2 - OIL PICK-UP TUBE
Fig. 6 Remove Extension Housing
1 - REAR CASE HALF
2 - EXTENSION HOUSING
Fig. 8 Remove Oil Pump
1 - REAR CASE HALF
2 - REAR OUTPUT SHAFT
3 - OIL PUMP
Fig. 9 Remove Case Half Bolts
1 - FRONT CASE HALF
2 - REAR CASE HALF
3 - BOLTS
21 - 546 TRANSFER CASE - NV273DR
TRANSFER CASE - NV273 (Continued)
Page 2250 of 2627
(4) Remove the rear output shaft bearing inner
snap-ring (Fig. 10) from the output shaft using suit-
able snap-ring pliers.
(5) Remove the rear output shaft bearing inner
snap-ring (Fig. 11) from the output shaft.
(6) Loosen rear case with pry tool to break sealer
bead. Insert tool at each end of case (Fig. 12).
(7) Unseat rear case from alignment dowels.
(8) Remove the rear case from the front case (Fig.
13).
Fig. 10 Remove Rear Bearing Inner Snap-Ring
1 - OUTPUT SHAFT
2 - REAR CASE HALF
3 - SNAP-RING
Fig. 11 Remove Rear Bearing Inner Snap-Ring
1 - OUTPUT SHAFT
2 - REAR CASE HALF
3 - SNAP-RING
Fig. 12 Separate Front and Rear Case Halves
1 - FRONT CASE HALF
2 - REAR CASE HALF
Fig. 13 Remove Rear Case Half
1 - FRONT CASE HALF
2 - REAR CASE HALF
DRTRANSFER CASE - NV273 21 - 547
TRANSFER CASE - NV273 (Continued)
Page 2251 of 2627
FRONT OUTPUT SHAFT AND DRIVE CHAIN
(1) Remove the oil pick-up tube (Fig. 14) and
screen from the front case half.
(2) Remove the front output shaft drive sprocket
retaining ring (Fig. 15).
(3) Remove the rear output shaft drive sprocket
retaining ring (Fig. 16).(4) Pull front sprocket (Fig. 17), rear sprocket, and
chain upward until clear of the front and rear output
shaft sprocket splines.
(5) Remove chain and sprockets as an assembly.
Fig. 14 Remove Oil Pick-Up Tube and Screen
1 - FRONT CASE HALF
2 - OIL SCREEN
3 - PICK-UP TUBE
Fig. 15 Remove Front Output Shaft Sprocket
Retaining Ring
1 - FRONT OUTPUT SHAFT
2 - DRIVE SPROCKET
3 - RETAINING RING
Fig. 16 Remove Rear Output Shaft Sprocket
Retaining Ring
1 - REAR OUTPUT SHAFT
2 - DRIVE SPROCKET
3 - RETAINING RING
Fig. 17 Remove Drive Chain and Sprockets
1 - FRONT CASE HALF
2 - CHAIN
3 - DRIVE SPROCKETS
21 - 548 TRANSFER CASE - NV273DR
TRANSFER CASE - NV273 (Continued)
Page 2252 of 2627
SHIFT FORKS AND MAINSHAFT
(1) Remove the bolts (Fig. 18) that hold the shift
motor assembly to the transfer case.
(2) Remove the shift motor assembly (Fig. 19) from
the transfer case.(3) Remove the sector support with Socket 9033.
(4) Loosen detent plug (Fig. 20).
(5) Remove detent plug, spring, and plunger (Fig.
21). Note that the plug has an O-ring seal. Remove
and discard this seal.
Fig. 18 Remove Shift Motor Assembly Bolts
1 - TRANSFER CASE
2 - SHIFT MOTOR ASSEMBLY
3 - BOLTS
Fig. 19 Remove Shift Motor Assembly From
Transfer Case
1 - TRANSFER CASE
2 - SHIFT MOTOR ASSEMBLY
Fig. 20 Loosen the Detent Plug
1 - FRONT CASE HALF
2 - DETENT PLUG
Fig. 21 Remove Detent plug, Spring, and Plunger
1 - FRONT CASE HALF
2 - DETENT PLUG
3 - SPRING
4 - PLUNGER
DRTRANSFER CASE - NV273 21 - 549
TRANSFER CASE - NV273 (Continued)
Page 2253 of 2627
(6) Using a screw mounted in a slide hammer,
remove the front output shaft seal.
(7) Remove the front output shaft snap-ring (Fig.
22).
(8) Remove front output shaft from bearing in case
(Fig. 23).(9) Pull mainshaft assembly out of input gear,
mode sleeve, and case (Fig. 24).
(10) Remove mode fork, mode sleeve, and shift rail
as assembly (Fig. 25). Note which way the sleeve fits
in the fork (long side of sleeve goes to front or the
points on the sleeve teeth go to the rear of case).
Fig. 22 Remove Front Output Shaft Bearing Inner
Snap-Ring
1 - FRONT CASE HALF
2 - SNAP-RING
Fig. 23 Remove Front Output Shaft
1 - FRONT CASE
2 - FRONT OUTPUT SHAFT
Fig. 24 Remove Mainshaft Assembly
1 - FRONT CASE HALF
2 - MAINSHAFT ASSEMBLY
Fig. 25 Mode Fork And Sleeve Removal
1 - MODE SLEEVE
2 - MODE FORK AND RAIL
21 - 550 TRANSFER CASE - NV273DR
TRANSFER CASE - NV273 (Continued)
Page 2254 of 2627
(11) Remove range fork and hub as an assembly
(Fig. 26). Note fork position for installation reference.
(12) Remove the shift sector (Fig. 27).MAINSHAFT
(1) Remove the clutch gear (Fig. 28) from the out-
put shaft.
(2) Remove the mode hub retaining ring (Fig. 29)
from the mainshaft.
Fig. 29 Remove Mode Hub Retaining Ring
1 - MAINSHAFT
2 - MODE HUB
3 - RETAINING RING
Fig. 26 Range Fork And Hub Removal
1 - RANGE HUB
2 - RANGE FORK
Fig. 27 Remove Shift Sector
1 - SHIFT SECTOR
Fig. 28 Remove Clutch Gear
1 - OUTPUT SHAFT
2 - CLUTCH GEAR
3 - MODE HUB
DRTRANSFER CASE - NV273 21 - 551
TRANSFER CASE - NV273 (Continued)
Page 2255 of 2627
(3) Remove the mode hub (Fig. 30) from the main-
shaft.
(4) Remove the drive sprocket drive hub (Fig. 31)
from the mainshaft.INPUT AND PLANETARY GEAR
(1) Remove input gear seal with suitable screw
and slide hammer.
(2) Remove input gear retaining ring (Fig. 32) with
heavy duty snap-ring pliers.
(3) Place front case in horizontal position. Then
remove input gear and low range gear as an assem-
bly (Fig. 33). Tap gear out of bearing with plastic
mallet, if necessary.
Fig. 30 Remove Mode Hub
1 - MAINSHAFT
2 - MODE HUB
Fig. 31 Remove the Drive Sprocket Drive Hub
1 - MAINSHAFT
2 - DRIVE SPROCKET DRIVE HUB
Fig. 32 Remove Input Gear Retaining Ring
1 - INPUT GEAR
2 - RETAINING RING
Fig. 33 Remove Input Planetary Assembly
1 - FRONT CASE
2 - INPUT PLANETARY ASSEMBLY
21 - 552 TRANSFER CASE - NV273DR
TRANSFER CASE - NV273 (Continued)
Page 2256 of 2627
(4) Remove snap-ring that retains input gear in
the low range gear (Fig. 34).
(5) Remove retainer (Fig. 35).
(6) Remove front thrust plate (Fig. 36).
(7) Remove input gear (Fig. 37).
Fig. 37 Remove Input Gear From Planetary
1 - INPUT GEAR
2 - LOW RANGE PLANETARY
Fig. 34 Remove Input Gear Retaining Ring
1 - INPUT GEAR
2 - RETAINING RING
Fig. 35 Remove Input Gear Retainer
1 - INPUT GEAR
2 - RETAINER
Fig. 36 Remove Input Gear Thrust Plate
1 - INPUT GEAR
2 - THRUST PLATE
DRTRANSFER CASE - NV273 21 - 553
TRANSFER CASE - NV273 (Continued)