Necessary equipment
J-25070 Jet dryer
Disassembly order
1. Remove transfer case from vehicle. See «Transfer case» in this section.
2. Remove O-ring (1) distribution box.
3. Remove the cork (2) transfer box filler hole and plug (3) drain hole of the transfer case.
4. Remove the transfer box heat shield mounting bolts and heat shield (4).
5. Using a suitable puller, remove the shield (1) front wheel drive shaft.
6. Remove retainer (2) front wheel drive.
7. Heat the end of the transfer case case with a J-25070 jet dryer to facilitate removal of the front wheel drive intermediate shaft.
8. Remove intermediate shaft (3) front wheel drive from the transfer case.
9. Heat the drive housing flange area with a J-25070 jet dryer to facilitate removal of the transfer case rear output shaft housing.
Important: Position 2 screwdrivers or 2 mounting levers in the drive housing flange area to facilitate removal.
10. Remove bolts (1) crankcase shaft rear output drive transfer case and crankcase (2) from the transfer box.
11. Remove adjusting shim (3) rear output shaft of the transfer case.
12. Remove sealing ring (4) transfer box rear output shaft housing and discard it.
13. Remove 11 bolts (1) fastening halves of the transfer case and the right side of the transfer case (2).
14. Remove transfer case seal (3) from transfer box (2).
15. Remove input shaft (4) transfer box and shaft (5) transfer case rear output drive on the left side of the transfer case.
Important: Dowel pins (6) transfer case halves should only be replaced if damaged. Check the box for similar damage.