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Condition Possible Cause Correction
Lubricant leaking from output shaft
seal or vent.1) Transfer case overfilled. 1) Drain lubricant to the correct
level.
2) Vent closed or restricted. 2) Clear or replace vent as
necessary.
3) Output shaft seals damaged or
installed incorrectly.3) Replace seal as necessary.
Check to ensure that another
component, the propeller shaft slip
yoke for example, is not causing
damage to seal.
Abnormal tire wear. 1) Extended operation on hard, dry
surfaces in the 4H position.1) Operate vehicle in the 2H
position on hard, dry surfaces.
REMOVAL
1. Raise and support vehicle.
2. Remove skid plate, if equipped. (Refer to 13 - FRAMES & BUMPERS/FRAME/TRANSFER CASE SKID PLATE
- REMOVAL)
3. Position drain oil container under transfer case.
4. Remove transfer case drain plug and drain lubricant into container.
5. Disconnect vent hose and transfer case position sensor connector.
6. Disconnect shift rod from grommet in transfer case shift lever, or from floor shift arm whichever provides easy
access. Use channel lock style pliers to press rod out of lever grommet.
7. Support transmission with jack stand.
8. Mark front and rear propeller shafts for assembly reference.
9. Remove front and rear propeller shafts. (Refer to 3 - DIFFERENTIAL & DRIVELINE/PROPELLER SHAFT/PRO-
PELLER SHAFT - REMOVAL)
10. Support transfer case with suitable jack. Secure transfer case to jackwith safety chains.
11. Remove nuts attaching transfer case to transmission.
12. Move transfer case assembly rearward until free of transmission outputshaft.
13. Lower jack and move transfer case from under vehicle.
DISASSEMBLY
Position transfer case in a shallow drain pan. Remove drain plug and drain any remaining lubricant remaining in
case.
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COMPANION FLANGE AND EXTENSION HOUSING
1. Install two bolts 180° apart into the front output
shaft companion flange.
2. Place holder (1) over the bolts (2) and against the
companion flange.
3. Remove and discard the front companion flange
nut.
4. Remove the companion flange from the front out-
put shaft. It may be necessary to use Pinion
Flange Remover 8992 to remove the companion
flange.
5. Use a suitable chisel or pry tool to remove the rear
extension housing (1) dust boot (2).
6. Use a suitable chisel or pry tool to remove the rear
extension housing seal.
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7. Remove rear extension (1) bolts (2).
8. Remove rear extension housing (2) from the rear
casehalf.Tapextensiononceortwicewithaplas-
tic mallet to break sealer bead and loosen it.
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OIL PUMP AND REAR CASE
1. Disengage the oil pump pick-up tube (2) from the
oil pump (1).
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 (3) from the rear output shaft
(2).
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3. Remove rear case (2)-to-front case (1) bolts (3).
4. Remove the rear output shaft bearing inner snap-
ring (3) from the output shaft (1) using suitable
snap-ring pliers.
5. Remove the rear output shaft bearing inner snap-
ring (3) from the output shaft (1).
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6. Loosen rear case (2) with pry tool to break sealer
bead. Insert tool at each end of case.
7. Unseat rear case from alignment dowels.
8. Remove the rear case (2) from the front case (1).
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FRONT OUTPUT SHAFT AND DRIVE CHAIN
1. Remove the oil pick-up tube (3) and screen (2)
from the front case half (1).
2. Remove the shift rail spring (2) from the shift rail
(1).
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3. Remove the front output shaft (1) drive sprocket (2)
retaining ring (3).
4. Remove the rear output shaft (1) drive sprocket (2)
retaining ring (3).
5. Pull front sprocket (3), rear sprocket, and chain (2)
upward until clear of the front and rear output shaft
sprocket splines.
6. Remove chain and sprockets as an assembly.