TRANSFER ASSEMBLY DISASSEMBLY


  1. REMOVE DYNAMIC DAMPER


    1. A01GZNQ

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

  2. REMOVE TRANSFER CASE PLUG


    1. A01H0FG

      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. A01GYOE

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

  4. REMOVE TRANSFER DRAIN PLUG


    1. A01GY89

      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. A01H1AE

      Remove the breather plug from the front transfer case.

  6. REMOVE NO. 2 TRANSFER CASE PLUG


    1. A01GW6K

      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. A01H08ZE01

      Using SST, hold the companion flange in place.

      SST
      09213-58013
      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. A01GZBVE01

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

  8. REMOVE DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY


    1. A01H0Y8E01

      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. A01GYQ2E01

      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. A01H0JPE02

      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. A01GWBTE01

      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. A01GZYW

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

  11. REMOVE TRANSFER EXTENSION HOUSING


    1. A01H1G1

      Remove the 11 bolts and bracket.

    2. A01GZ6H

      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. A01GZDAE01

      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. A01GZ2DE01

      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. A01H10Z

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

  15. REMOVE DIFFERENTIAL CASE NEEDLE ROLLER BEARING


    1. A01GYKE

      Remove the bearing from the No. 1 differential case.

  16. REMOVE NO. 2 TRANSFER THRUST BEARING RACE


    1. A01H0MR

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

  17. REMOVE TRANSFER OUTPUT SHAFT SHIM


    1. A01GYIX

      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. A01GZPGE01

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

      SST
      09950-00020
      09950-00030

  20. REMOVE BREATHER OIL DEFLECTOR


    1. A01H0VD

      Remove the 2 bolts and oil deflector.

  21. REMOVE TRANSFER INPUT GEAR STOPPER SHAFT SNAP RING


    1. A01H0FF

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

  22. REMOVE TRANSFER INPUT GEAR STOPPER


    1. A01H27S

      Remove the gear stopper from the input shaft.

  23. REMOVE REAR TRANSFER CASE


    1. A01GYEJ

      Remove the 7 bolts and rear transfer case.

  24. REMOVE TRANSFER IDLER GEAR ASSEMBLY


    1. A01GWR7

      Remove the idler gear from the front transfer case.

  25. REMOVE TRANSFER OIL PUMP DRIVE SHAFT


    1. A01H09Q

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

  26. REMOVE TRANSFER COUNTER GEAR ASSEMBLY


    1. A01H17Y

      Remove the counter gear from the front transfer case.

  27. REMOVE TRANSFER FRONT DRIVE GEAR ASSEMBLY


    1. A01H0D7

      Remove the drive gear from the front transfer case.

  28. REMOVE TRANSFER FRONT DRIVE GEAR PIN


    1. A01GWPT

      Remove the drive gear pin from the front transfer case.

  29. REMOVE TRANSFER INPUT SHAFT


    1. A01H1ZI

      Remove the input shaft from the drive gear.

  30. REMOVE TRANSFER OIL SEAL RING


    1. A01H1JE

      Remove the oil seal ring from the input shaft.

  31. REMOVE DRIVE PINION COMPANION FLANGE OIL SEAL


    1. A01H1R0E01

      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. A01GWQCE01

      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. A01H1K8E01

      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. A01H095E01

      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. A01H2ACE01

      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. A01GXOC

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

  35. REMOVE NO. 1 TRANSFER OIL STRAINER


    1. A01GXF9

      Remove the oil strainer from the front transfer case.

  36. REMOVE TRANSFER OIL COOLER RELIEF VALVE


    1. A01H1BW

      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. A01GXXJ

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

  37. REMOVE TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL


    1. A01GXPYE01

      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. A01GZFSE01

      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. A01H1AVE01

      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. A01GY1CE01

      for Front Transfer Case Side:


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

        SST
        09612-65014   ( 09612-01020 )
    2. A01GZKFE01

      for Rear Transfer Case Side:


      1. 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. A01H1FO

      Remove the oil seal ring from the sleeve.

  42. REMOVE TRANSFER FRONT CASE OIL SEAL


    1. A01GWYFE01

      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. A01H0XKE01

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

    2. A01GZIR

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

    3. A01H17TE01

      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. A01GYI3

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

    2. A01H224E01

      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.