Transfer case repair — general information

Repairing a transfer case is quite a complicated procedure to do it yourself. In this case, it is necessary to disassemble and assemble many small elements. It is necessary to accurately measure many gaps and, if necessary, adjust them by adding or removing shims or snap rings. Thus, the most rational thing is to remove and install the box by an experienced mechanic, but to perform repair procedures you should contact a specialized workshop. You may be able to get a replacement refurbished box - consult your technical representative on this issue. It should be noted that replacing with a remanufactured transfer case may be more cost effective than rebuilding the existing unit.

However, transfer case repair can be done by an experienced mechanic if you have the necessary specialized equipment and follow the procedures carefully.

Retaining ring removers are required for repairs (external and internal), bearing pullers, impact puller, punch set, dial gauge and possibly a hydraulic press. In addition, a level, stable workbench and a vice are required.

When disassembling the transfer case, it is necessary to mark the original positions of the parts, so that later you can assemble the box correctly and without wasting time.

Before starting repairs, you should clearly understand which transfer case assembly is faulty. Some problems are closely related to the failure of certain parts of the box. Refer to section «Determining the causes of malfunctions» at the beginning of this manual.