How to disassemble a Jeep Transfer Case

Got a clunk or rattle in your transfer case, maybe 4wd doesn't work anymore. Does it "Row Hop" around corners? I will show you how to disassemble a Jeep transfer case.

Difficulty: Moderate

Instructions

Things You'll Need:

• Hand Tools including wrenches, sockets, hammer
• Snap Ring Pliers
• Work Bench

1. 

   Remove the rubber access plug on top of the tail housing. This is where you will gain access to the output shaft bearing snap ring.

2. 

   Remove all the extension housing bolts.

3. 

   Expand the snap ring into the housing and remove the extension housing case.

4. 

   Remove the snap rings from both sides of the output shaft bearing. Remove the bearing and place it in a clean area. Remove the oil pump and set aside.

5. 

   Remove the retaining snap ring for the viscous coupling.

6. 

   Tap with a hammer on the areas that extend from the case, be careful not to hit too hard as you can break the aluminum case easily. You will hear a change in the sound as the case separates. You may need a pry bar to assist with this step.

7. 

   Remove the snap ring for front drive shaft output gear.

8. 

   Slide the viscous clutch coupling off of the out put shaft and place in a clean location.

9. 

   Wiggle the gear and you may have to gently tap on the back of the front output shaft to free the output shaft drive gear. It should begin sliding off.

10. 

    Slide off the chain, drive gear and front output drive gear. Note the green arrows pointing at the roller bearings that will fall out when removing the gears, collect all of these and place into a clean towel as you will them for reassembly.

11. 

    Remove the shifter shaft then pull the output shaft and the shift fork from the case.

12. 

    Remove the input shaft seal retainer and remove the input shaft snap ring.

13. 

    Remove the nut from the front output flange, remove the flange and tap the front output shaft into the case to remove it.

14. 

    Remove the planetary carrier from the case, this is the input shaft as well.

15. 

    Now you have fully disassembled your transfer case, replace worn or damaged parts.

Tips & Warnings

• Drain the transfer case before removing it and there will be less mess where you work on it.
• Wear safety glasses when working to prevent eye injuries.

[spencers87]

on 10/10/2008 I'm removing my 231 transfer case from my 87 yj. Can i do it myself, will I have to remove the transmission? Can I get to the bolts and or nuts without removing the transmission? Your article on how to disassemble was great. Can you how to remove and install?