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.
Transfer Case - Vehicles With: Manual Shift Transfer Case: Disassembly
- Using a transmission adjustable mounting arm, secure the transfer case to the bench. Use the General Equipment: Adjustable Mounting Arm
- Remove the transfer case rear seal. Refer to: Transfer Case Rear Seal .
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NOTE: The transfer case bolts are self tapping, and it is normal to find metal shavings while removing the cover.
Remove the transfer case bolts.
- Using the pry bosses, separate the transfer case covers.
- Remove the shift lock hub snap ring.
- Visually notice alignment, remove the shift fork lock hub.
- Remove the lock hub shift fork assembly.
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NOTE: Remove the drive chain and sprockets as an assembly.
Remove the drive chain and sprockets.
- Remove the center bearing support assembly.
- Remove the shift rail.
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NOTE: The pump assembly is not repairable.
Remove the oil pump assembly and magnet.
- Remove the output shaft.
- Remove the shift fork assembly.
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NOTE: Replace the inner planet carrier needle bearing if necessary.
Remove the planet carrier thrust bearing and the front planet carrier.
- Remove the ring gear circlip and the ring gear.
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NOTE: The manual shift cam is serviced as an assembly. Do not disassemble the shift cam assembly.
Remove the manual shift assembly.
- Loosen the shift lever set screw.
- remove the shift lever.
- Remove the shift guide plate and guide plate spring arm.
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NOTE: Do not let the front output shaft fall while removing the snap ring or damage to the component may occur.
Remove the output shaft circlip and the out put shaft.
- Remove and discard the front input shaft seal and the front output shaft seal.
- Using the special tool with the Slide Hammer, remove the rear output shaft bearing. Use Special Service Tool: 308-047 (T77F-1102-A) Remover, Bearing Cup. Use the General Equipment: Slide Hammer
- Using the special tool and a Slide Hammer, remove the front output shaft support bearing. Use Special Service Tool: 307-318 Remover, Stator Bearing. Use the General Equipment: Slide Hammer
- Using the special tool with the Slide Hammer, remove the front output shaft bearing. Use Special Service Tool: 308-047 (T77F-1102-A) Remover, Bearing Cup. Use the General Equipment: Slide Hammer
- Using the special tool and a Slide Hammer, remove the front planet carrier bearing. Use Special Service Tool: 308-047 (T77F-1102-A) Remover, Bearing Cup. Use the General Equipment: Slide Hammer
- Clean and inspect the components of the transfer case for damage and install new components as necessary.
- Remove the center support bearing. Use the General Equipment: Copper Hammer Use the General Equipment: Punch
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.