adjacent parts. Also, make sure all straps, wires, and other attachments have
been disconnected.
2.2.2 Transfer Case Disassembly
After removing the transfer case, drain any remaining oil. Clean the outside of the
housing and mount the unit securely on a clean workbench. Make sure the transfer
case will not fall off the bench during the disassembly procedure.
Figure 8-25 - Transfer case with a two-piece or split-type housing.
If not removed previously, remove the drive shaft yokes. Most drive shaft yokes are
secured to the output shafts with large nuts. The nuts can be removed with the proper
wrench. The yoke should be held securely with a special tool or a large pipe wrench as
the nut is loosened. Mark the front and back yokes to ease reassembly.
Remove the speedometer gear and housing from the transfer case. Also, remove
electrical switches and other external transfer case parts as necessary.
If the transfer case housing is the common two-piece type as the one shown in
Figure
8-25
, remove the bolts holding the front and rear halves together. Notice the
identification tag on the transfer case. The same as previously discussed with the
transmission, this should be used to order parts and to determine which service
specifications you should use. The halves can then be split apart. If the gasket sticks,
pry the halves apart with pry bars (
Figure 8-26
). If the housing is a one-piece type, the
front and rear retainers that hold the input shaft bearings should be removed to gain
access to the internal parts (
Figure 8-27
). As you see in
View A
, most bearing retainers
can be unbolted from the case and then lightly pried up, always being careful not to
damage any machined parts.
View B
shows the basic procedure for removing the
bearing retainer and shaft on the one-piece case. Always use a soft-face hammer to
avoid damaging the shaft or gears.
After accessing the internal parts, remove any snap rings that hold the transfer case
gears to the shaft or secure the shafts to the housing. Then remove the internal parts as
NAVEDTRA 14050A
8-36
