Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
Section 10 (Mp3023 Transfer Case (Service Information)): Disassembly
| 1 - HOUDINI RETAINING RING |
| 2 - INPUT BALL BEARING |
| 3 - RETAINING RING |
| 4 - CARRIER LOCK PLATE |
| 5 - FRONT CARRIER THRUST WASHER |
| 6 - INPUT GEAR ASSEMBLY |
| 7 - CARRIER THRUST SHIM |
| 8 - PLANETARY CARRIER ASSEMBLY |
| 9 - RANGE SLEEVE |
| 10 - MAINSHAFT ASSEMBLY |
| 11 - OIL PUMP ASSEMBLY |
| 12 - REAR THRUST WASHER |
| 13 - REAR WEAR SLEEVE |
| 14 - REAR OUTPUT FLANGE |
| 15 - O-RING SEAL |
| 16 - FLANGE NUT |
| 17 - SCREW |
| 18 - SHIFT MOTOR |
| 19 - WORM SHAFT OIL SEAL |
| 20 - RETAINING RING |
| 21 - RETAINING RING |
| 22 - BALL BEARING |
| 23 - WORM SHAFT |
| 24 - SHIFT RAIL |
| 25 - RANGE FORK PAD |
| 26 -RANGE FORK |
| 27 - SLEEVE WASHER |
| 28 - SPRING |
| 29 - BRACKET ASSEMBLY |
| 30 - RETAINING RING |
| 31 - BARREL CAM |
| 32 - SHIFT SHAFT ASSEMBLY |
| 33 - BUSHING |
| 34 - CLUTCH CAM |
| 35 - GEAR |
| 36 - COUPLING |
| 37 - RETAINING RING |
| 38 - BEARING |
| 39 - REAR CASE HALF ASSEMBLY |
| 40 - BOLT |
| 41 - SCREW |
| 42 - RADIAL SEAL RING |
| 43 - SENSOR |
| 44 - SCREW |
| 45 - RETAINING RING |
| 46 - SCREW |
| 47 - IDENTIFICATION TAG |
| 48 - FILL/DRAIN PLUG |
| 49 - REAR BEARING |
| 50 - SHIFT SHAFT BEARING RETAINING RING |
| 51 - SHIFT SHAFT BEARING |
| 52 - TUBE & SCREEN ASSEMBLY |
| 53 - O-RING SEAL |
| 54 - MAGNET |
| 55 - SCREW |
| 56 - SPRING |
| 57 - DETENT POPPET |
| 58 - CHAIN |
| 59 - SPROCKET |
| 60 - RETAINING RING |
| 61 - FRONT BEARING |
| 62 - FRONT CASE HALF ASSEMBLY |
| 63 - DOWEL BUSHING |
| 64 - RADIAL SEAL RING |
| 65 - FRONT WEAR SLEEVE |
| 66 - FRONT OUTPUT FLANGE |
| 67 -RETAINING RING |
| 68 - INPUT SEAL |
| 69 - VENT |
If the transfer case assembly is being reconditioned (clutch/seal replacement) or replaced, it is necessary to perform the Quick Learn Procedure using the Scan Tool.
- Place the transfer case in a shallow pan and remove the fill and drain plugs to drain the remainder of the fluid.
- Using Holder (special tool #C-3281, Holder, Flange) (1), remove the rear flange (2) nut.
- Remove the rear output flange from the main shaft. If necessary, use a suitable 2 or 3 jaw puller to remove the output flange.
- Remove encoder screws and the encoder from the transfer case.
- Remove the shift shaft snap ring from the transfer case.
- Remove shift motor bolts and the shift motor from the transfer case.
- Remove the O-ring from the shift motor.
- Using a suitable pry tool, remove shift motor seal from the transfer case.
- Remove the worm shaft snap ring from the transfer case.CAUTION:
Carefully unthread (rotate clockwise) the worm shaft to remove it from the transfer case. Failure to follow this caution may result in parts damage.
- Remove the worm shaft from the transfer caseNOTE:
Some prying may be necessary to break the seal between the front and rear case. Use care to not damage the sealing surfaces.
- Remove the bolts retaining the rear housing to the front housing and separate the housings.
- Remove the output shaft thrust washer.
- Remove the oil pump assembly.
- Remove oil tube (1) from the oil pump and remove the O-ring (2).
- Remove the pick-up magnet from the magnet pocket.NOTE:
For ease of installation note the orientation of the worm shaft drive gear inner splines to the shift shaft outer splines.
- Remove the worm drive gear.NOTE:
For ease of installation note the orientation of the clutch cam inner splines to the shift shaft outer splines.
- Remove the clutch cam.
- Remove the clutch upper snap ring.
- Remove the clutch shim.
- Remove the thrust collar.
- Remove the upper thrust bearing race.
- Remove the upper thrust bearing.
- Remove the upper shift lever.
- Remove the shift lever balls.
- Remove the lower shift lever.
- Remove the lower thrust bearing.
- Remove the lower thrust bearing race.
- Remove the clutch apply piston.NOTE:
For ease of installation note the assembly orientation of the 4 identical springs.
- Remove the clutch return springs.
- Remove the clutch pack.
- Remove the inner clutch hub.
- Remove the clutch drum thrust washer (1) and snap ring (2).
- Remove the outer clutch drum from the main shaft drive sprocket.
- Remove the front drive sprocket, main shaft drive sprocket and drive chain as one.
- Remove the shift shaft spacer.NOTE:
For ease of installation note the orientation of the barrel cam inner splines to the shift shaft outer splines.
- Remove the barrel cam.
- Remove the shift shaft.
- Remove the main shaft from the transfer case.
- Remove the detent assembly.NOTE:
For ease of assembly note the orientation of the shift fork to the shift rail.
- Remove the range shift rail assembly and range sleeve. Remove the rail, bracket, spring and washers from the shift fork.
- Remove the retaining snap ring from the front output shaft.
- Remove the front output shaft from the transfer case.
- Using a suitable pry tool or a screw mounted in a slide hammer, remove the input gear seal. Remove the input gear snap ring.
- Remove the input planetary gear assembly from the front housing.
- Remove the snap-ring holding the input gear into the planetary gear.
- Remove the lock plate from the input and planetary gear assembly.
- Remove the thrust washer from the input and planetary gear assembly.
- Remove the input gear from the planetary gear.
- Remove the tabbed thrust washer from the planetary gear.
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.