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: Electronic Shift Transfer Case: Disassembly
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NOTE: Seal all openings before cleaning the transfer case exterior. This will prevent entry of dirt and water, which may cause damage to internal components.
Using a transmission adjustable mounting arm, secure the transfer case to the bench. Clean the transfer case with solvent and dry with compressed air. Use the General Equipment: Adjustable Mounting Arm
- Remove and discard the transfer case rear output shaft seal.
- Remove the bolt and the vibration damper from the transfer case.
- Remove the coil wire pin from the electrical connector.
- Remove the inner retainer from the wire connector.
- Press the release tab and remove the coil wire pin.
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- Loosen the transfer case shift motor bracket nuts.
- Remove the transfer case shift motor bracket bolt.
- Remove the transfer case shift motor bolts.
- Remove the transfer case shift motor.
- Remove the coil nuts and washers.
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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.
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NOTE: Use care not damage the field coil wire.
Using the pry bosses, separate the transfer case covers.
- Remove the dowel pins.
- Remove the transfer case field coil.
- Remove the field coil housing snap ring.
- Remove the field coil housing.
- Remove the lock up hub, shift fork and shift fork spring.
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NOTE: Remove the lockup hub assembly as a single unit. If disassembly is required, proceed with the following.
Disassemble the lockup hub assembly.
- Remove the lockup hub snap ring.
- Separate the lockup collar.
- Remove the armature.
- Separate the 2 lockup springs.
- Separate the lockup hub.
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NOTE: Remove the drive chain and sprockets as an assembly.
Remove the drive chain and sprockets.
- Remove the sprocket thrust washer.
- Remove the magnet from its slot in the case.
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NOTE: The pump assembly is not repairable.
Remove the oil pump assembly.
- Remove the shift rail.
- Remove the shift fork.
- Remove the output shaft.
- Remove the reduction hub.
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NOTE: The electric shift cam is serviced as an assembly. Do not disassemble the shift cam assembly.
Remove the electric shift cam assembly.
- Remove the planet carrier thrust bearing.
- Remove the ring gear circlip.
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NOTE: Replace the inner planet carrier needle bearing if necessary.
Remove the front planet carrier.
- Remove the ring gear.
- Remove the front output shaft seal dust cover.
- Remove the front output shaft.
- Remove and discard the front output shaft seal.
- Remove and discard the input shaft seal.
- Using the special tool with the Slide Hammer, remove the planet carrier bearing.
Use Special Service Tool: 308-047 (T77F-1102-A) Remover, Bearing Cup.
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 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
- Remove and discard the shift shaft seal.
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NOTE: Clean and inspect the components of the transfer case for damage and install new components as necessary.
Clean the transfer case with solvent and dry with compressed air.
NO RELATED
Use the Manual With the Right Hardware
Pair factory procedures with proven DIY tools so the instructions are easier to execute.
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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.