Page 4089 of 5267
6. Using a suitable pry tool (2), remove the slinger (1)
from the output shaft using care not to damage the
shaft.
7. Using a screw and a slide hammer, remove the
front output shaft seal.
REAR EXTENSION
1. Remove rear extension (1) bolts.
2. Remove rear extension housing (1). Tap extension
once or twice with a plastic mallet to break sealer
bead and loosen it.
Page 4090 of 5267
3. Remove output bearing (2) retaining ring (3) with
heavy duty snap-ring pliers.
OIL PUMP AND REAR CASE
1. Remove rear case(1)-to-front case (2) bolts (3).
2. Loosen rear case (1) with pry tool to break sealer
bead. Insert tool in slot (3) at each end of case.
Page 4091 of 5267
3. Unseat rear case (1) from alignment dowels.
4. Remove rear case and oil pump assembly from
front case.
CAUTION: Do not remove the bolts holding the oil
pump cover to the rear case half. The oil pump
cover is aligned to the rear output shaft bearing
inner race and will becomemis-aligned if the bolts
are loosened. If the transfer case failure has gen-
erated any debris which may have become
trapped in the oil pump, the rear case and oil
pump assembly MUST be replaced.
FRONT OUTPUT SHAFT AND DRIVE CHAIN
1. Remove shift rail (1) cup (3) and spring (2).
2. Remove front sprocket (1) retaining ring (2).
Page 4092 of 5267
3. Pull mainshaft (3), front sprocket (1) and chain out-
ward about 25.4 mm (1-inch) simultaneously.
4. Remove chain from mainshaft drive sprocket and
remove front sprocket and chain as assembly.
SHIFT FORKS AND MAINSHAFT
1. Remove the transfer case position switch (2).
2. Loosen detent plug (2).
3. Remove detent plug (2), spring (3), and plunger
(4). Note that the plug has an O-ring seal. Remove
and discard this seal.
Page 4093 of 5267
4. Remove the front output shaft (1) snap-ring (2).
5. Remove front output shaft (2) from bearing in the
front case (1).
6. Pull mainshaft assembly (2) out of input gear,
mode sleeve, and front case (1).
Page 4094 of 5267
7. Remove mode fork (1), mode sleeve (3), and shift
rail (2) as assembly. Note which way the sleeve fits
in the fork (long side of sleeve goes to front).
8. Remove range fork retaining ring.
9. Remove range fork (2) and hub (1) as an assem-
bly. Note fork position for installation reference.
10. Remove the shift sector support (1).
Page 4095 of 5267
11. Remove shift sector (1).
MAINSHAFT
1. Remove the drive sprocket retaining ring (2) from
the output shaft (1).
2. Remove the drive sprocket (3) thrust washer (2)
from the output shaft (1).
Page 4096 of 5267
3. Remove drive sprocket (2) from the output shaft
(1).
4. Remove the clutch gear (2) from the output shaft
(1).
Remove the sprocket hub (2) from the output shaft
(1).