DISASSEMBLY AND ASSEMBLY

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DISASSEMBLY AND ASSEMBLY

Special Tool(s)

Transfer Case — All Wheel Drive

Holding Fixture, Transmission

(AWD)

307-003 (T57L-500-B) Special Tool(s)

Remover, Bearing Cup 308-047 (T77F-1102-A)

Slide Hammer

100-001 (T50T-100-A)

Installer, Wheel Hub Bearing Cup 204-020 (T73T-1202-A) 2 Jaw Puller 205-D026 (D80L-1002-L) or equivalent Puller, Bearing 205-D064 (D84L-1123-A)

Installer, Input Shaft Oil Seal 308-186 (T90T-7127-B)

Remover, Stator Bearing 307-318 (T94P-77001-KH)

Material

Item Specification

Silicone Gasket and WSE-M4G323-A4 Holding Fixture, Drive Pinion _Sealant

Flange _{F7AZ-19554-EA}

205-126 (T78P-4851-A)

MERCON_Automatic _MERCON

Transmission Fluid XT-2-QDX

Adapter for 303-224 (Handle) 205-153 (T80T-4000-W)

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4. Index-mark the rear output shaft flange and the CAUTION: Discard all seals after

upper output shaft. removing them.

1. WARNING: Make sure the special

tool lock pin is secure.

Using the special tool, secure the transfer case to a bench.

2. Remove the dampener.

3. If not done previously, remove the drain plug and drain the fluid.

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5. Remove the parts in the order indicated in the following illustration and table.

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Item Part Number Description Item Part Number Description 31 7C016 Dust deflector 1 7045 Output flange nut

Disassembly Note ₃₂ ₇₀₂₅ _Bearing

Assembly Note _{Disassembly Note}

Assembly Note 2 7B368 Output shaft yoke washer

33 7B215 Yoke to flange seal 3 7B214 Output flange

Assembly Note

4 7052 Oil seal

34 7B215 Input shaft seal 5 7A443 Bolt (17 req’d)

35 7025 Bearing

6 7005 Case

Disassembly Note

6. To assemble, reverse the disassembly procedure.

Assembly Note

7 7A153 Upper output shaft and ring

Item 1: Output Flange Nut Disassembly Note gear

Disassembly Note _1. _{Using the special tool to hold the output flange,}

Assembly Note _{remove the nut.}

8 7917 Snap ring

9 7025 Bearing

10 7B215 Yoke to flange seal Assembly Note 11 7C122 Snap ring

12 7061 Upper output shaft 13 7L290 Oil scoop

14 7R141 Snap ring

15 7025 Bearing

Disassembly Note

16 7A771 Torx_{head screw (4 req’d)}

17 7F123 Damper snubber

18 7A385 Output shaft thrust washer

Item 6: Case Disassembly Note 19 7A398 Front planetary gear assembly

1. Using a pry bar, separate the rear case from the

20 7A385 Thrust washer

front case.

21 7177 Upper drive sprocket

Disassembly Note • Pry only at the transfer case pry bosses.

22 7D063 Overdrive sun gear 23 7A029 Drive chain

24 7177 Lower drive sprocket Assembly Note 25 7A385 Thrust washer

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Item 7: Upper Output Shaft and Ring Gear Item 21: Upper Drive Sprocket Disassembly

Disassembly Note Note

1. Remove the upper output shaft and the ring 1. Remove the upper drive sprocket, overdrive sun

gear. gear, drive chain and the lower drive sprocket

as one assembly.

• Expand the snap ring.

Item 28: Bearing Disassembly Note

1. Using the special tools, remove the bearing.

Item 29: Snap Ring Disassembly Note

1. Hold the front output shaft while removing the snap ring.

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Item 24: Lower Drive Sprocket Assembly Note

1. Assemble the overdrive sun gear, the upper

Item 33: Seal Assembly Note drive sprocket, lower drive sprocket and the

drive chain. 1. Using the special tool, install the seal.

• Align the blind spline on the lower drive sprocket with the narrow spline on the overdrive sun gear.

Item 32: Bearing Assembly Note

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2. Install the overdrive sun gear, the upper

sprocket, the lower sprocket and the drive chain as an assembly.

Item 10: Yoke to Flange Seal Assembly Note

1. Using the special tool, install the seal.

Item 6: Case Assembly Note

1. CAUTION: Applying excess silicone

gasket and sealant can damage the internal components.

Apply a 3 mm (0.125 in) bead of silicone gasket and sealant on the rear case mating

Item 7: Upper Output Shaft and Ring Gear _surface.

Assembly Note

1. Install the upper output shaft and ring gear in the rear case half.

• Expand the snap ring. Install the upper output shaft and ring gear assembly.

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Item 1: Output Flange Nut Assembly Note

1. While holding the flange with the special tool, tighten the nut.