Page 4225 of 5267
3. Remove the front propeller shaft seal boot (1)
retaining clamp (2).
4. Remove the front propeller shaft seal boot (1).
5. Remove the front output shaft seal slinger (1) by
bending (2) the slinger away from the transfer
case.
6. Using a suitable pry tool, remove the slinger 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.
Page 4226 of 5267
REAR EXTENSION
1. Remove rear extension housing (1) bolts.
2. Remove rear extension housing (1). Tap extension
once or twice with a plastic mallet to break sealer
bead and loosen it.
3. Remove output shaft bearing (2) retaining ring (3)
with heavy duty snap-ring pliers.
Page 4227 of 5267
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.
3. Unseat rear case from alignment dowels.
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 inner
bearing race and will become mis-aligned if the
bolts are loosened. If the transfer case failure has
generated any debris which may have become
trapped in the oil pump. the rear case and oil
pump assembly MUST be replaced.
4. Remove rear case (1) and oil pump assembly from
front case (2).
5. Remove the oil pump pickup tube.
Page 4228 of 5267
FRONT OUTPUT SHAFT AND DRIVE CHAIN
1. Remove shift rail (1) spring (2).
2. Remove front sprocket (1) retaining ring (2).
3. Remove the mode fork (2) and sleeve (3) from the
shift rail (1) and mainshaft.
Page 4229 of 5267
4. Remove the rear output shaft retaining ring (2)
from the output shaft (1).
5. Pull front sprocket (1), rear sprocket (3), and chain
(2) outward simultaneously.
6. Remove front sprocket, rear sprocket, and chain as
an assembly.
SHIFT FORKS AND MAINSHAFT
1. Loosen detent plug (2).
2. Remove detent plug (2), spring (3), and plunger
(4). Note that the plug has an O-ring seal. Remove
and discard this seal.
Page 4230 of 5267
3. Remove the front output shaft (1) snap-ring (2).
4. Remove front output shaft from bearing in case.
5. Remove the mainshaft and differential assembly (2)
from the input gear and transfer case (1).
6. Remove the shift rail (1) from the range fork
assembly (2) and the front case.
Page 4231 of 5267
7. Remove range fork (2) and hub (1) as an assem-
bly. Note fork position for installation reference.
8. Remove shift sector (1).
9. Remove the shift sector o-ring (2).
Page 4232 of 5267
MAINSHAFT
1. Remove intermediate clutch shaft (2) snap-ring (1).
2. Remove the intermediate clutch shaft thrust ring
(1).
3. Remove the intermediate clutch shaft (1).