Transfer case components
1 - oil seal; 2 - bolt; 3 - drain plug; 4 — adapter body; 5 - sealing ring; 6 - oil gutter; 7 — adjusting washer; 8 — ring gear bearing; 9 — inner race; 10 — outer race; 11 — ring gear bolt; 12 — ring gear; 13 — drive gear; 14 — oil filler hole plug; 15 — oil deflector; 16 — transfer case housing; 17 — branch pipe for ventilation hose; 18 - cork; 19 — drive gear bushing washer; 20 — drive gear; 21 — front bearing of the drive gear; 22 - deformable spacer sleeve; 23 — drive gear sleeve; 24 - dust cover; 25 — rear bearing of the drive gear; 26 — connecting flange; 27 — drive gear nut.
Disassembly
- Loosen the mounting bolts (arrows) of the drive gear bushing (see figure HM.27.008).
- Temporarily tighten the 2 bolts. To remove the pinion bushing, tap the coupling flange with a plastic hammer.
- Remove the drive pinion bushing adjusting washer.
- Unscrew the drive gear nut.
- Using a mandrel (Pr) and a press, press the drive gear down from the drive gear bushing (see figure HM.27.009).
- Remove the drive gear.
- Remove the sealing ring from the pinion bushing.
- Using a flat-blade screwdriver, remove the oil seal.
Caution: Be careful not to damage the pinion bushing.
- Remove the inner race of the rear pinion bearing.
- Using the puller (Pr), remove the outer race of the rear bearing of the drive pinion.
- Using a puller, remove the outer race of the front pinion bearing.
- Remove the deformable spacer sleeve from the drive gear.
- Using a special tool (Pr), press the inner race of the front pinion bearing down from the pinion gear.
- Unscrew the mounting bolts (arrows) of the adapter body.
- Remove the adapter housing by tapping it with a plastic hammer.
- Remove the sealing ring.
- Using a flat-blade screwdriver, remove the oil seal.
Caution: Be careful not to damage the adapter body.
- To remove the adjusting washer and the outer race of the ring gear bearing, use a brass rod to knock the adjusting washer out of the recess in the adapter body.
- Remove the oil gutter (1).
- Unscrew the drain plug.
- Remove the ring gear from the transfer case housing.
- Using a mandrel and a special tool (Pr), press the inner race of the ring gear bearing off the adapter body.
- Using a mandrel and puller (Pr), remove the inner race of the ring gear bearing from the ring gear.
- Loosen the ring gear mounting bolts.
- To remove the ring gear, tap it with a plastic hammer.
- Using a puller (Pr), remove the oil seal from the ring gear.
- Using a flat-blade screwdriver, remove the oil seal.
Caution: Be careful not to damage the transfer case housing.
- Remove the oil deflector (1).
- To remove the adjusting washer and the outer race of the ring gear bearing, use a brass rod to evenly tap the adjusting washer out of the two recesses in the transfer case housing.
- Remove the oil filler plug and the vent hose connection.