TRANSFER ASSEMBLY DISASSEMBLY


  1. REMOVE DYNAMIC DAMPER


    1. A01GL4A

      Remove the bolt, 2 washers and dynamic damper from the rear transfer case.

  2. REMOVE TRANSFER CASE PLUG


    1. A01GN57

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

  3. REMOVE FILLER PLUG


    1. A01GICH

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

  4. REMOVE TRANSFER DRAIN PLUG


    1. A01GMDF

      Using a 10 mm hexagon socket wrench, remove the drain plug and O-ring from the front transfer case.

  5. REMOVE TRANSFER CASE BREATHER PLUG


    1. A01GL8D

      Remove the breather plug from the front transfer case.

  6. REMOVE NO. 2 TRANSFER CASE PLUG


    1. A01GM8A

      Using a 17 mm straight hexagon wrench, remove the case plug and gasket from the rear transfer case.

  7. REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY


    1. A01GHKDE01

      Using SST, hold the companion flange in place.

      SST
      09213-58014
      09330-00021

      Tech Tips

      Use bolts of size M8 x P1.25 with a length of approximately 55 mm (2.16 in.) or equivalent to secure the companion flange.

    2. A01GMHBE03
      Text in Illustration
      *a Hold
      *b Turn

      Remove the companion flange bolt and companion flange from the transfer assembly.

  8. REMOVE DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY


    1. A01GKF5E01

      Using SST and a hammer, loosen the staked part of the transfer output shaft nut.

      SST
      09930-00010

      Note


      • Completely loosen the staked part of the transfer output shaft nut.

      • Do not damage the threads of the No. 1 differential case.

      • Use SST with the tapered surface facing the No. 1 differential case.

      • Do not grind the end of SST with a grinder or other tool.

    2. A01GKC2E02
      Text in Illustration
      *a Hold
      *b Turn

      Using SST, hold the companion flange in place.

      SST
      09330-00021
      09950-30012   ( 09955-03040 )

    3. Using a 30 mm socket wrench, remove the transfer output shaft nut.

    4. A01GN8UE03
      Text in Illustration
      *a Hold
      *b Turn

      Using SST, remove the companion flange.

      SST
      09950-30012   ( 09951-03010, 09953-03010, 09954-03010, 09955-03040 )

  9. REMOVE TRANSFER EXTENSION HOUSING OIL SEAL


    1. A01GK0LE01

      Using SST, remove the oil seal.

      SST
      09308-00010

      Note

      Be careful not to damage the surface of the transfer extension housing that contacts the oil seal.

  10. REMOVE NO. 1 DIFFERENTIAL CASE HOLE SNAP RING


    1. A01GNE2

      Using needle-nose pliers, remove the snap ring from the extension housing.

  11. REMOVE TRANSFER EXTENSION HOUSING


    1. A01GJMC

      Remove the 11 bolts and bracket.

    2. A01GNN0

      Using an oil pan seal cutter, remove the extension housing.

      Note

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

  12. REMOVE NO. 1 TRANSFER THRUST BEARING RACE


    1. A01GJV2E02
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver, remove the bearing race from the extension housing.

      Tech Tips

      Tape the screwdriver tip before use.

      Note

      Be careful not to damage the surface which contacts the bearing race.

  13. REMOVE TRANSFER OUTPUT SHAFT CYLINDRICAL ROLLER BEARING


    1. A01GMQRE01

      Using SST and a press, remove the bearing (outer race) from the extension housing.

      SST
      09950-60010   ( 09951-00460 )
      09950-70010   ( 09951-07100 )

      Tech Tips

      The bearing (inner race) is removed from the No. 1 differential case sub-assembly.

  14. REMOVE TRANSFER OUTPUT SHAFT WASHER


    1. A01GLH9

      Remove the 2 shaft washers from the No. 1 differential case.

  15. REMOVE DIFFERENTIAL CASE NEEDLE ROLLER BEARING


    1. A01GL3I

      Remove the bearing from the No. 1 differential case.

  16. REMOVE NO. 2 TRANSFER THRUST BEARING RACE


    1. A01GMXL

      Remove the bearing race from the No. 1 differential case.

  17. REMOVE TRANSFER OUTPUT SHAFT SHIM


    1. A01GKHV

      Remove the shim from the No. 1 differential case.

  18. REMOVE NO. 1 DIFFERENTIAL CASE SUB-ASSEMBLY


    1. Remove the No. 1 differential case from the rear transfer case.

  19. REMOVE TRANSFER OUTPUT SHAFT CYLINDRICAL ROLLER BEARING


    1. A01GL9KE02
      Text in Illustration
      *a Hold
      *b Turn

      Using SST, remove the bearing (inner race) from the No. 1 differential case.

      SST
      09950-00020
      09950-00030

  20. REMOVE BREATHER OIL DEFLECTOR


    1. A01GL6D

      Remove the 2 bolts and oil deflector.

  21. REMOVE TRANSFER INPUT GEAR STOPPER SHAFT SNAP RING


    1. A01GNI6

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

  22. REMOVE TRANSFER INPUT GEAR STOPPER


    1. A01GL3H

      Remove the gear stopper from the input shaft.

  23. REMOVE REAR TRANSFER CASE


    1. A01GIH0

      Remove the 7 bolts and rear transfer case.

  24. REMOVE TRANSFER IDLER GEAR ASSEMBLY


    1. A01GMG7

      Remove the idler gear from the front transfer case.

  25. REMOVE TRANSFER OIL PUMP DRIVE SHAFT


    1. A01GHQM

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

  26. REMOVE TRANSFER COUNTER GEAR ASSEMBLY


    1. A01GLYK

      Remove the counter gear from the front transfer case.

  27. REMOVE TRANSFER FRONT DRIVE GEAR ASSEMBLY


    1. A01GJ4O

      Remove the drive gear from the front transfer case.

  28. REMOVE TRANSFER FRONT DRIVE GEAR PIN


    1. A01GJ0Y

      Remove the drive gear pin from the front transfer case.

  29. REMOVE TRANSFER INPUT SHAFT


    1. A01GJH2

      Remove the input shaft from the drive gear.

  30. REMOVE TRANSFER OIL SEAL RING


    1. A01GI42

      Remove the oil seal ring from the input shaft.

  31. REMOVE DRIVE PINION COMPANION FLANGE OIL SEAL


    1. A01GI0AE02
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver and hammer, tap out the oil seal from the companion flange.

      Tech Tips

      Tape the screwdriver tip before use.

  32. REMOVE TRANSFER IDLER GEAR BEARING


    1. A01GNE0E02
      Text in Illustration
      *a Hold
      *b Turn

      for Front Transfer Case Side:

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

      SST
      09950-40011   ( 09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04021, 09957-04010, 09958-04011 )
      09950-60010   ( 09951-00420, 09951-00540, 09952-06010 )
    2. A01GMTDE02
      Text in Illustration
      *a Hold
      *b Turn

      for Rear Transfer Case Side:

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

      SST
      09950-40011   ( 09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04021, 09957-04010, 09958-04011 )
      09950-60010   ( 09951-00440, 09951-00540, 09952-06010 )

  33. REMOVE TRANSFER COUNTER GEAR BEARING


    1. A01GI51E01
      Text in Illustration
      *a Hold
      *b Turn

      for Front Transfer Case Side:

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

      SST
      09950-00020
      09950-00030
      09950-40011   ( 09957-04010 )
      09950-60010   ( 09951-00280, 09951-00440, 09952-06010 )
    2. A01GIYTE01
      Text in Illustration
      *a Hold
      *b Turn

      for Rear Transfer Case Side:

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

      SST
      09950-00020
      09950-00030
      09950-40011   ( 09957-04010 )
      09950-60010   ( 09951-00360, 09951-00500, 09952-06010 )

  34. REMOVE TRANSFER OIL SEPARATOR


    1. A01GK6O

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

  35. REMOVE NO. 1 TRANSFER OIL STRAINER


    1. A01GKTS

      Remove the oil strainer from the front transfer case.

  36. REMOVE TRANSFER OIL COOLER RELIEF VALVE


    1. A01GIQH

      Remove the bolt, relief valve plate and relief valve compression spring from the front transfer case.

      Note

      Be careful to prevent the relief valve compression spring from jumping out.

    2. A01GLRT

      Using a magnet hand, remove the relief valve from the front transfer case.

  37. REMOVE TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL


    1. A01GIAXE02
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver and hammer, tap out the oil seal from the front transfer case.

      Note

      Be careful not to damage the surface which contacts the oil seal.

  38. REMOVE TRANSFER IDLER GEAR BEARING


    1. A01GL9AE02
      Text in Illustration
      *a Hold
      *b Turn

      for Front Transfer Case Side:

      Using SST, remove the 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 )
      09950-60010   ( 09951-00290 )
    2. A01GNZUE02
      Text in Illustration
      *a Hold
      *b Turn

      for Rear Transfer Case Side:

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

      SST
      09950-40011   ( 09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04071, 09957-04010 )
      09950-60010   ( 09951-00380 )

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

  39. REMOVE TRANSFER OIL PUMP PLATE SUB-ASSEMBLY


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

    2. Remove the transfer oil pump plate pin from the transfer oil pump plate.

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

  40. REMOVE TRANSFER COUNTER GEAR BEARING


    1. A01GKD8E03
      Text in Illustration
      *a Hold
      *b Turn

      for Front Transfer Case Side:

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

      SST
      09612-65014   ( 09612-01020 )
    2. A01GMTGE02
      Text in Illustration
      *a Hold
      *b Turn

      for Rear Transfer Case Side:

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

      SST
      09950-40011   ( 09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04071, 09957-04010 )
      09950-60010   ( 09951-00420 )

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

  41. REMOVE FORWARD CLUTCH DRAM OIL SEAL RING


    1. A01GIZE

      Remove the oil seal ring from the sleeve.

  42. REMOVE TRANSFER FRONT CASE OIL SEAL


    1. A01GNGWE02
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver, pry out the oil seal from the front transfer case.

      Note

      Be careful not to damage the surface which contacts the oil seal.

      Tech Tips

      Tape the screwdriver tip before use.

  43. REMOVE TRANSFER FRONT DRIVE GEAR CYLINDRICAL ROLLER BEARING (for Front Transfer Case Side)


    1. A01GN4HE02
      Text in Illustration
      *1 Roller
      *2 Roller Cage

      Using a screwdriver, remove the bearing rollers and roller cage.

    2. A01GNOJ

      Remove the drive gear bearing and race from the front transfer case.

    3. A01GLLIE02
      Text in Illustration
      *a Hold
      *b Turn

      Using SST, remove the bearing from the front transfer case.

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

  44. REMOVE TRANSFER OUTPUT SHAFT CYLINDRICAL ROLLER BEARING (for Rear Transfer Case Side)


    1. A01GNBK

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

    2. A01GMJDE01

      Using SST and a press, remove the bearing from the rear transfer case.

      SST
      09950-60010   ( 09951-00540, 09951-00650, 09952-06010 )
      09950-70010   ( 09951-07100 )

      Note

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