TRANSFER ASSEMBLY DISASSEMBLY

PROCEDURE


  1. DISCONNECT NO. 2 GROUND WIRE

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  2. REMOVE TRANSFER CASE PLUG


    1. B004XPFC02
      *a for Front Transfer Case Upper Side
      *b for Front Transfer Case Lower Side

      Using a 6 mm hexagon socket wrench, remove the 2 transfer case plugs and 2 O-rings from the front transfer case.

  3. REMOVE TRANSFER FILLER PLUG


    1. B004VHY

      Using a 10 mm hexagon socket wrench, remove the transfer filler plug and transfer filler plug gasket from the rear transfer case.

  4. REMOVE TRANSFER DRAIN PLUG


    1. B004R4G

      Using a 10 mm hexagon socket wrench, remove the transfer drain plug and transfer drain plug gasket from the rear transfer case.

  5. REMOVE TRANSFER CASE BREATHER PLUG


    1. B004YTD

      Remove the transfer case breather plug from the rear transfer case.

  6. REMOVE NO. 2 TRANSFER CASE PLUG


    1. B004W9I

      Using a 17 mm straight hexagon wrench, remove the No. 2 transfer case plug and transfer case plug gasket from the rear transfer case.

  7. REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY

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  8. REMOVE TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL

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  9. REMOVE DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

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  10. REMOVE TRANSFER EXTENSION HOUSING OIL SEAL

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  11. REMOVE TRANSFER EXTENSION HOUSING


    1. B004XB6

      Remove the 11 bolts.

    2. B004RR5

      Using an oil pan seal cutter, remove the transfer extension housing sub-assembly.

      Note

      Be careful not to damage the contact surface of the transfer extension housing sub-assembly or rear transfer case.

  12. REMOVE NO. 1 TRANSFER THRUST BEARING RACE


    1. B004V67C04
      *1 Protective Tape

      Using a screwdriver with its tip wrapped with protective tape, remove the No. 1 transfer thrust bearing race from the transfer extension housing.

      Note

      Be careful not to damage the extension housing sub-assembly.

  13. REMOVE TRANSFER OUTPUT SHAFT WASHER


    1. B004WH7

      Remove the 2 transfer output shaft washer from the No. 1 differential case sub-assembly.

  14. REMOVE DIFFERENTIAL CASE NEEDLE ROLLER BEARING


    1. B004W6V

      Remove the differential case needle roller bearing from the No. 1 differential case sub-assembly.

  15. REMOVE NO. 2 TRANSFER THRUST BEARING RACE


    1. B004RNM

      Remove the No. 2 transfer thrust bearing race from the No. 1 differential case sub-assembly.

  16. REMOVE TRANSFER OUTPUT SHAFT SHIM


    1. B004SE0

      Remove the transfer output shaft shim from the No. 1 differential case sub-assembly.

  17. REMOVE NO. 1 DIFFERENTIAL CASE SUB-ASSEMBLY


    1. Remove the No. 1 differential case sub-assembly from the rear transfer case.

  18. REMOVE NO. 1 DIFFERENTIAL CASE SUB-ASSEMBLY HOLE SNAP RING


    1. B004X32

      Using needle nose pliers, remove the No. 1 differential case sub-assembly hole snap ring from the transfer extension housing sub-assembly.

  19. REMOVE TRANSFER OUTPUT SHAFT CYLINDRICAL ROLLER BEARING


    1. B004UEKN04

      Using SST and a press, remove the transfer output shaft cylindrical roller bearing from the transfer extension housing sub-assembly.

      SST
      09950-60011   ( 09951-00460 )
      09950-70010   ( 09951-07100 )

      Note

      Be careful not to damage the transfer extension housing sub-assembly.

  20. REMOVE BREATHER OIL DEFLECTOR


    1. B004RCU

      Remove the 2 bolts and the breather oil deflector from the rear transfer case.

  21. REMOVE TRANSFER INPUT GEAR STOPPER SHAFT SNAP RING


    1. B004T8I

      Using a snap ring expander, remove the transfer input gear stopper snap ring from the transfer input shaft.

  22. REMOVE TRANSFER INPUT GEAR STOPPER


    1. B004RM9

      Remove the transfer input gear stopper from the transfer input shaft.

  23. REMOVE REAR TRANSFER CASE


    1. B004TNK

      Remove the 7 bolts and the rear transfer case cover from the front transfer case.

  24. REMOVE TRANSFER IDLER GEAR ASSEMBLY


    1. B004XAC

      Remove the transfer idler gear assembly from the front transfer case.

  25. REMOVE TRANSFER OIL PUMP DRIVE SHAFT


    1. B004ROZ

      Remove the transfer oil pump drive shaft from the front transfer case.

  26. REMOVE TRANSFER COUNTER GEAR ASSEMBLY


    1. B004SN2

      Remove the transfer counter gear assembly from the front transfer case.

  27. REMOVE TRANSFER FRONT DRIVE GEAR ASSEMBLY


    1. B004SCL

      Remove the transfer front drive gear assembly from the front transfer case.

  28. REMOVE TRANSFER FRONT DRIVE GEAR PIN


    1. B004UEY

      Remove the transfer front drive gear pin from the front transfer case.

  29. REMOVE TRANSFER INPUT SHAFT


    1. B004ULD

      Remove the transfer input shaft from the transfer front drive gear assembly.

  30. REMOVE TRANSFER OIL SEAL RING


    1. B004RH9

      Remove the transfer oil seal ring from the transfer input shaft.

  31. REMOVE DRIVE PINION COMPANION FLANGE OIL SEAL


    1. B004WJ8C03
      *a Protective Tape

      Using a screwdriver wrapped in protective tape, remove the drive pinion companion flange oil seal from the drive pinion companion flange.

      Note

      Be careful not to damage the drive pinion companion flange sub-assembly.

  32. REMOVE TRANSFER IDLER GEAR BEARING


    1. for Front Transfer Case Side:


      1. B004TFPC04
        *a Turn
        *b Hold

        Using SST, remove the transfer idler gear bearing (inner race) from the transfer idler gear assembly.

        SST
        09950-40011   ( 09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04021, 09957-04010, 09958-04011 )
        09950-60011   ( 09951-00420, 09951-00540, 09952-06010 )

        Note

        Be careful not to damage the transfer idler gear assembly.

      2. B004UZLC04
        *a Turn
        *b Hold

        Using SST, remove the transfer idler gear bearing (outer race) from the front transfer case.

        SST
        09950-40011   ( 09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04071, 09957-04010 )
        09950-60011   ( 09951-00290 )

        Note

        Be careful not to damage the front transfer case.

    2. for Rear Transfer Case Side:


      1. B004WNVC04
        *a Turn
        *b Hold

        Using SST, remove the transfer idler gear bearing (inner race) from the transfer idler gear assembly.

        SST
        09950-40011   ( 09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04021, 09957-04010, 09958-04011 )
        09950-60011   ( 09951-00420, 09951-00540, 09952-06010 )

        Note

        Be careful not to damage the idler gear bearing.

      2. B004XOTC04
        *a Turn
        *b Hold

        Using SST, remove the transfer idler gear bearing (outer race) from the rear transfer case.

        SST
        09950-40011   ( 09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04071 )
        09950-60011   ( 09951-00380 )

        Note

        Be careful not to damage the rear transfer case.

    3. Remove the transfer idler gear shim from rear transfer case.

  33. REMOVE TRANSFER COUNTER GEAR BEARING


    1. for Front Transfer Case Side:


      1. B004TL8C02
        *a Turn
        *b Hold

        Using SST, remove the transfer counter gear bearing (inner race) from the transfer counter gear assembly.

        SST
        09950-00020
        09950-00030
        09950-40011   ( 09957-04010 )
        09950-60011   ( 09951-00280, 09951-00440, 09952-06010 )

        Note

        Be careful not to damage the transfer counter gear assembly.

      2. B004T0AC04
        *a Turn
        *b Hold

        Using SST, remove the transfer counter gear bearing (outer race) from the front transfer case.

        SST
        09612-65014   ( 09612-01020 )

        Note

        Be careful not to damage the front transfer case.

    2. for Rear Transfer Case Side:


      1. B004XYDC02
        *a Turn
        *b Hold

        Using SST, remove the transfer counter gear bearing (inner race) from the transfer counter gear assembly.

        SST
        09950-00020
        09950-00030
        09950-40011   ( 09957-04010 )
        09950-60011   ( 09951-00360, 09951-00500, 09952-06010 )

        Note

        Be careful not to damage the transfer counter gear assembly.

      2. B004YU8C04
        *a Turn
        *b Hold

        Using SST, remove the transfer counter gear bearing (outer race) from the front transfer case.

        SST
        09950-40011   ( 09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04071, 09957-04010 )
        09950-60011   ( 09951-00420 )

        Note

        Be careful not to damage the rear transfer case.

    3. Remove the transfer counter gear shim from rear transfer case.

  34. REMOVE TRANSFER OIL SEPARATOR


    1. B004TLH

      Remove the 3 bolts and transfer oil separator from the front transfer case.

  35. REMOVE NO. 1 TRANSFER OIL STRAINER


    1. B004UMU

      Remove the No. 1 transfer oil strainer from the front transfer case.

  36. REMOVE TRANSFER OIL PUMP PLATE SUB-ASSEMBLY


    1. B004YB5C02
      *1 Transfer Oil Pump Plate Sub-assembly
      *2 Front Transfer Case
      *3 Transfer Oil Pump Plate Pin
      *4 Transfer Oil Pump Drive Rotor
      *5 Transfer Oil Pump Driven Rotor

      Using an air gun, gradually apply air and remove the transfer oil pump plate sub-assembly from the front transfer case.

    2. Remove the transfer oil pump plate pin from the transfer oil pump plate sub-assembly.

    3. Remove the transfer oil pump drive rotor and transfer oil pump driven rotor from the front transfer case.

  37. REMOVE FORWARD CLUTCH DRUM OIL SEAL RING


    1. B004WP6

      Remove the forward clutch drum oil seal ring from the front transfer case.

  38. REMOVE TRANSFER FRONT CASE OIL SEAL


    1. B004TDRC02
      *1 Protective Tape

      Using a screwdriver with its tip wrapped with protective tape, remove the transfer front case oil seal from the front transfer case.

      Note

      Do not damage the transfer front case oil seal installation surface.

  39. REMOVE TRANSFER FRONT DRIVE GEAR ASSEMBLY CYLINDRICAL ROLLER BEARING


    1. for Front Transfer Case Side:


      1. B004RWUC04
        *1 Roller
        *2 Roller Cage

        Using a screwdriver, remove the transfer front drive gear assembly cylindrical roller bearing rollers and roller cage.

      2. B004W30

        Remove the transfer front drive gear bearing and No. 3 transfer thrust bearing race from the front transfer case.

      3. B004VOSC04
        *a Turn
        *b Hold

        Using SST, remove the transfer front drive gear assembly cylindrical roller bearing (outer race) from the front transfer case.

        SST
        09649-17010
        09950-40011   ( 09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04041, 09957-04010 )

        Note

        Be careful not to damage the front transfer case.

    2. for Rear Transfer Case Side:


      1. B004YH7

        Using needle-nose pliers, remove the transfer front drive gear snap ring from the rear transfer case.

      2. B004VD1N04

        Using SST and a press, remove the transfer front drive gear assembly cylindrical roller bearing from the rear transfer case.

        SST
        09950-60011   ( 09951-00540, 09951-00650, 09952-06010 )
        09950-70010   ( 09951-07100 )

        Note


        • Be careful of the straight pins when placing the case on the press.

        • Be careful not to damage the rear transfer case.