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Disassemble Proportional
Differential Lockout and
Front Output Shaft Assembly
1. Rotate the transfer case in the repair stand so that
the declutch assembly is facing upward. Figure 14.
2. If the declutch assembly has a declutch indicator
switch, remove the declutch indicator switch from the
shift plate.
3. Remove the capscrews and washers from the
declutch shift plate.
4. Remove the setscrew from the declutch shift fork.
5. Remove the capscrews and washers from the cover
of the declutch piston. Remove the cover.
6. Remove the declutch piston and the return spring.
7. Remove the quad seal from the declutch piston.
Discard the quad seal. Install a new quad seal at
assembly.
8. Remove the shift fork.
9. Remove the two internal output cage mounting
capscrews and washers.
10. Remove the external output cage mounting
capscrews and washers.
CAUTION
Be careful not to damage the shims when
removing the bearing cage. Damaged shims can
cause fluid leakage.
11. Lift the bearing cage and shaft assembly from the
housing. If there are any shims in between the
transfer case housing and bearing cage, keep
them. You will use these shims at assembly.
Replace damaged or worn shims.
12. Remove the oil and dirt seals from the bearing cage
assembly.
13. Remove the ball bearing retention snap ring.
14. Remove the declutch output shaft and ball bearing
assembly in the direction of the oil seal and snap
ring bores.
!
15. Remove the sliding declutch collar.
16. Remove the ball bearing from the declutch output
shaft.
Disassemble Housing Halves
1. Remove the bolt, washers and nuts from the outer
flange of the housing.
2. Separate the case halves with a pry bar. Figure 14.
Figure 14
WARNING
To avoid serious personal injury and possible
damage to components, be very careful when
using lifting devices.
•
Inspect to make sure that the lifting loops or
lifting straps are not damaged.
•
Always use both lifting loops and lifting straps
when lifting.
•
Do not subject lifting loops or lifting straps to any
shock or drop loading.
3. Use the lifting loops or eyebolts to lift and remove the
top half of the case.
!
Pro Gear and Transmission • 906 W. Gore St. Orlando, FL 32805 • 1 (877) 776-4600 / (407) 872-1901 • [email protected]