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Service Information: Disassembly

Fig 1: Remove/Install Damper Bolts
GC0027425Courtesy of DAIMLERCHRYSLER CORP.
1 - BOLTS
2 - DAMPNER
3 - REAR HOUSING
  1. Remove the bolts (1) holding the damper (2) to the rear case (3). See Fig 1.
    Fig 2: Remove/Install Damper
    GC0027426Courtesy of DAIMLERCHRYSLER CORP.
    1 - DAMPER
    2 - REAR HOUSING
  2. Remove the damper (1) from the rear case (2). See Fig 2.
    Fig 3: Fill/Drain Plug And I.D. Tag Locations
    GC0027410Courtesy of DAIMLERCHRYSLER CORP.
    1 - I.D. TAG
    2 - FILL PLUG
    3 - DRAIN PLUG
  3. Position transfer case on shallow drain pan. Remove drain plug (3) and drain lubricant. See Fig 3.
    Fig 4: Remove/Install Rear Output Shaft Nut
    GC0027411Courtesy of DAIMLERCHRYSLER CORP.
    1 - HOLDER C-3281
    2 - REAR OUTPUT SHAFT FLANGE
  4. Using Holder C-3281 (1), remove the rear output flange (2) nut. See Fig 4.
    Fig 5: Remove/Install Rear Output Shaft Flange
    GC0027412Courtesy of DAIMLERCHRYSLER CORP.
    1 - REAR OUTPUT SHAFT FLANGE
    2 - REAR OUTPUT SHAFT
  5. Remove the rear output shaft flange (1) from the main shaft (2). If flange is difficult to remove by hand, remove it with bearing splitter, or with standard two jaw puller. Be sure puller tool is positioned securely on flange. See Fig 5.
    Fig 6: Remove/Install Rear Housing Bolts
    GC0027413Courtesy of DAIMLERCHRYSLER CORP.
    1 - REAR HOUSING
    2 - BOLTS
    3 - FRONT HOUSING
  6. Support transfer case so rear case is facing upward and the input gear is not contacting the work surface.
  7. Remove bolts (2) holding front case to rear case (1). See Fig 6.
    Fig 7: Remove/Install Rear Housing
    GC0027422Courtesy of DAIMLERCHRYSLER CORP.
    1 - REAR HOUSING
    2 - FRONT HOUSING
    NOTE: Be careful not to damage the front and rear case sealing surfaces.
  8. Loosen rear case with a case splitter or suitable tool to break sealer bead. Insert case splitter or suitable tool only into notches provided at each end of case.
  9. Remove rear case (1) from front case (2). See Fig 7.
    Fig 8: Front Drive Sprocket Retaining Ring Removal/Installation
    GC0027414Courtesy of DAIMLERCHRYSLER CORP.
    1 - FRONT OUTPUT SHAFT
    2 - RETAINING RING
  10. Remove mainshaft drive sprocket retaining ring.
  11. Remove front output shaft drive sprocket retaining ring (2) from the front output shaft (1). See Fig 8.
    Fig 9: Remove/Install Front and Rear Drive Sprockets and Drive Chain
    GC0027415Courtesy of DAIMLERCHRYSLER CORP.
    1 - FRONT DRIVE SPROCKET
    2 - MAINSHAFT DRIVE SPROCKET
    3 - DRIVE CHAIN
  12. Remove the drive sprockets (1, 2) and the drive chain (3) as one. See Fig 9.
    Fig 10: Remove/Install Mainshaft and Differential Assembly
    GC0027416Courtesy of DAIMLERCHRYSLER CORP.
    1 - MAINSHAFT AND DIFFERENTIAL ASSEMBLY
    2 - FRONT HOUSING
  13. Remove the mainshaft and differential assembly (1) from the front case (2). See Fig 10.
    Fig 11: Remove/Install Input Gear Thrust Washer
    GC0027427Courtesy of DAIMLERCHRYSLER CORP.
    1 - THRUST WASHER
    2 - INPUT GEAR
  14. Remove the input gear thrust washer (1) from the input gear (2). See Fig 11.
    Fig 12: Remove/Install Chain Guide Screws
    GC0027423Courtesy of DAIMLERCHRYSLER CORP.
    1 - SCREWS
    2 - FRONT CASE
  15. Remove the screws (1) holding the chain guide rails to the front case (2). See Fig 12.
    Fig 13: Remove/Install Chain Guide
    GC0027424Courtesy of DAIMLERCHRYSLER CORP.
    1 - DRIVE CHAIN GUIDE
  16. Remove the drive chain guide (1) from the transfer case. See Fig 13.
    Fig 14: Remove/Install the Differential Snap-ring
    GC0027417Courtesy of DAIMLERCHRYSLER CORP.
    1 - DIFFERENTIAL SNAP-RING
  17. Remove the differential snap-ring (1). See Fig 14.
    Fig 15: Remove/Install the Differential
    GC0027418Courtesy of DAIMLERCHRYSLER CORP.
    1 - DIFFERENTIAL ASSEMBLY
    2 - MAINSHAFT
  18. Remove the differential assembly (1) from the mainshaft (2). See Fig 15.
    Fig 16: Removing/Installing Mode Hub and Retainer
    GC0006009Courtesy of DAIMLERCHRYSLER CORP.
    1 - DIFFERENTIAL ASSEMBLY
    2 - MODE HUB AND RETAINER
  19. Remove the mode hub (2) and mode hub retainer from the differential assembly (1). See Fig 16.
    Fig 17: Removing/Installing Retainer at Mode Hub
    GC0006010Courtesy of DAIMLERCHRYSLER CORP.
    1 - MODE HUB RETAINER
    2 - MODE HUB
  20. Remove the mode hub retainer (1) from the mode hub (2). See Fig 17.
    Fig 18: Remove/Install Front Output Shaft Retaining Ring
    GC0027420Courtesy of DAIMLERCHRYSLER CORP.
    1 - FRONT OUTPUT SHAFT
    2 - RETAINING RING
  21. Remove the retaining ring (2) from the front output shaft (1). See Fig 18.
    Fig 19: Remove/Install Front Output Shaft and Flange
    GC0027421Courtesy of DAIMLERCHRYSLER CORP.
    1 - FRONT HOUSING
    2 - FRONT OUTPUT SHAFT
  22. Remove the front output shaft assembly (2) from the front case (1) and the front output shaft front bearing. See Fig 19.
  23. Remove the front output shaft seal with a suitable pry tool or a screw mounted in a slide hammer.
    Fig 20: Remove/Install Input Gear
    GC0027419Courtesy of DAIMLERCHRYSLER CORP.
    1 - FRONT HOUSING
    2 - INPUT GEAR
  24. Remove the input gear (2) from the front case (1). See Fig 20.
  25. Remove the input shaft seal with a suitable pry tool or a screw mounted in a slide hammer.
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