Disassembly
DISASSEMBLY
EXTERNAL COMPONENTS
Fig. 17 Rear Case Half. New Process Models 231, 233 & 241 Transfer Cases:
Fig. 18 Front Case Half. New Process Models 231, 233 & 241 Transfer Cases:
Fig. 19 Transfer Case Exploded View. New Process Models 231, 233 & 241 Transfer Cases:
Clean
^ The transfer case extenor using solvent and a stiff brush.
Remove or Disconnect
1. Front output yoke nut (77), washer (76), rubber sealing washer (75) and front output yoke (74) from the front output shaft.
2. Vacuum switch (46) and 0-ring seal (47).
3. Poppet screw (68), poppet spring (71), and poppet plunger (70).
MAINSHAFT EXTENSION AND OIL PUMP HOUSING
Fig. 18 Front Case Half. New Process Models 231, 233 & 241 Transfer Cases:
Fig. 19 Transfer Case Exploded View. New Process Models 231, 233 & 241 Transfer Cases:
Remove or Disconnect
1. Rear extension bolts (3) and rear extension (4).
2. Bearing retainer snap ring (5) from the mainshaft (19).
3. Pump retainer housing bolts (7).
4. Pump retainer housing (8) from the rear case half (17).
5. Speedometer tone wheel (11) from the mainshaft (19).
6. Case bolts (3) from the case halves.
^ Note, the two longer case bolts and washers go into the doweled case holes (33).
Important
Some transfer case models have a bracket-attached to them by the case half bolts. These bolts are different from the others and must be put back into the correct holes.
^ Separate the case halves by inserting screwdrivers into the slots cast into the case ends and pry apart. Do not attempt to wedge the case halves apart at any point on the mating surfaces. Damage to the case may result.
^ Be careful not to damage the oil pump (12) (located in the rear case half) while removing the. rear case half (17).
INTERNAL COMPONENTS
Fig. 19 Transfer Case Exploded View. New Process Models 231, 233 & 241 Transfer Cases:
Fig. 20 Oil Pump, Pickup Tube & Screen. New Process Models 231, 233 & 241 Transfer Cases:
Fig. 21 Mode Fork & Shaft Assembly. New Process Models 231, 233 & 241 Transfer Cases:
Fig. 22 Shift Rail Assembly. New Process Models 231, 233 & 241 Transfer Cases:
Fig. 23 Input Gear Bearing Removal. New Process Models 231, 233 & 241 Transfer Cases:
Fig. 24 Front Output Shaft Rear Bearing Removal. New Process Models 231, 233 & 241 Transfer Cases:
Remove or Disconnect
Tools Required:
J 8092 Driver Handle
J 36370 Bearing Installer/Remover
J 29170 Bearing Remover
J 29369-1 Bearing Remover
J 9276-21 Adapter
J 2619-01 Slide Hammer
J 33790 Bearing Remover
Important
The annulus gear found in this transfer case is not serviceable or removable, and should only be replaced as a unit with the front case half. If the annulus gear is removed, damage will result to the case.
Fig. 20 Oil Pump, Pickup Tube & Screen. New Process Models 231, 233 & 241 Transfer Cases:
1. Oil pump (12) pickup tube (18), O-ring (14) and pump pickup filter (35) from the rear case half.
2. Fork shift spring.
3. Mainshaft (19), chain (58), and driven sprocket (22) from the front case half (45) as a unit. Mode shift fork (54) and shift rail (48) will be removed with the main shaft.
4. Retainer (snap ring) (83) from the mainshaft (19).
5. Synchronizer assembly (81).
Fig. 21 Mode Fork & Shaft Assembly. New Process Models 231, 233 & 241 Transfer Cases:
6. Drive sprocket (20) from the mainshaft (19).
Fig. 22 Shift Rail Assembly. New Process Models 231, 233 & 241 Transfer Cases:
7. Range shift fork (51) and range shift hub (34) from the planetary carrier (36).
^ It is necessary to rotate the sector shaft (55) to obtain clearance when removing the range fork (51).
8. Shift lever nut (63), washer (64), shift lever (65), sector and shaft assembly (55) plastic washer (66) and the O-ring seal(67) from the front case half (45).
9. Input bearing retainer bolts (43) and input bearing retainer (44) from the front case half (45).
10. Bearing retainer (snap ring) (39).
11. Planetary carrier (36) and the input gear (38) from the annulus gear (62) using a soft faced hammer.
12. Input bearing (40) from the front case half (45) using J 36370 and J 8092.
13. Drive sprocket bearings (82) from the drive sprocket (20) using J 29170 and J 8092.
Fig. 23 Input Gear Bearing Removal. New Process Models 231, 233 & 241 Transfer Cases:
14. Needle bearings (84) from the input gear (38) using J 29369-1, J 9276-21 and J 2619-01.
15. Front output shaft seal (72) from the front case half (45).
16. Front output bearing retainer ring (snap ring) (60).
17. Front output bearing (61) from the front case half (45) using J 33790 and J 8092.
18. Seal (1) from the mainshaft extension housing (4).
19. Seal (42) from the input bearing retainer (44).
Fig. 24 Front Output Shaft Rear Bearing Removal. New Process Models 231, 233 & 241 Transfer Cases:
20. Front output rear bearing (24) from the rear case half (17) using J 2619-01 and J 29369-2.
21. Mainshaft bearing (6) from the oil pump retainer (8) using J 33790.
22. Magnets (25) from the front case half (45).
Disassemble
^ Mark the location of the synchronizer hub and sleeve to aid in assembly. Synchronizer teeth must align with struts (30).
1. Main drive synchronizer stop ring (28) from the synchronizer sleeve (29).
2. Spring retainers (32) from the synchronizer hub (31).
3. Synchronizer hub (31) from the synchronizer (29).
4. Oil pump screws (79) from the oil pump (12).
Important
The oil pump is not a serviceable unit and should be replaced if it is defective.