TRANSFER ASSEMBLY DISASSEMBLY

PROCEDURE


  1. REMOVE PROPELLER SHAFT HEAT INSULATOR BRACKET SUB-ASSEMBLY


    1. A01XA26

      Remove the bolt and bracket.

  2. REMOVE TRANSFER OIL PUMP PLATE


    1. A01X981

      Remove the 4 bolts, oil pump plate and oil pump driven rotor.

      Note

      Do not drop the oil pump driven rotor.

    2. Remove the O-ring from the oil pump plate.

    3. A01X9G5

      Remove the transfer oil seal ring from the input shaft.

    4. A01X0TDE06
      *1 Oil Pump Drive Rotor

      Remove the oil pump drive rotor from the input shaft.

  3. REMOVE TRANSFER CASE STRAIGHT PIN


    1. A01XAUTE04
      *1 Transfer Case Straight Pin

      Remove the 2 straight pins.

      Note

      Do not drop the straight pins.

  4. REMOVE TRANSFER CASE PLUG


    1. A01X9YI

      Using a 10 mm hexagon wrench, remove the case plug, compression spring, ball and relief valve seat.

  5. REMOVE TRANSFER OIL PUMP PLATE OIL SEAL


    1. A01WZ1U

      Using a screwdriver, pry out the oil seal from the oil pump plate.

      Note

      Be careful not to damage the oil seal and oil pump plate contact surfaces.

      Tech Tips

      Tape the screwdriver tip before use.

  6. REMOVE FRONT OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY


    1. A01X34QE04

      Using SST and a hammer, release the staked part of the nut.

      SST
      09930-00010   ( 09931-00010, 09931-00020 )

      Note


      • Be sure to use SST with the tapered surface facing the shaft.

      • Do not grind the tip of SST with a grinder, etc.

      • Completely loosen the staked part of the nut when removing it.

      • Do not damage the threads of the transfer driven sprocket.

    2. A01XBGME01

      Using SST to hold the companion flange, remove the lock nut.

      SST
      09330-00021
    3. A01X7FVE01

      Using SST, remove the companion flange.

      SST
      09950-40011   ( 09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04051, 09957-04010, 09958-04011 )

    4. Remove the O-ring from the companion flange.

  7. REMOVE TRANSFER OUTPUT SHAFT DUST DEFLECTOR


    1. A01X5DRE01

      Using SST and a press, remove the transfer output shaft dust deflector.

      SST
      09950-00020
      09950-60010   ( 09951-00340, 09951-00470, 09952-06010 )
      09950-70010   ( 09951-07100 )

      Note

      Do not drop the front output shaft companion flange sub-assembly.

  8. REMOVE TRANSFER CASE FRONT OIL SEAL

    Click here

  9. REMOVE REAR OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY


    1. A01X38GE01

      Using SST and a hammer, release the staked part of the nut.

      SST
      09930-00010   ( 09931-00010, 09931-00020 )

      Note


      • Be sure to use SST with the tapered surface facing the shaft.

      • Do not grind the tip of SST with a grinder, etc.

      • Completely loosen the staked part of the nut when removing it.

      • Do not damage the threads of the rear transfer output shaft.

    2. A01WZUHE01

      Using SST to hold the companion flange, remove the lock nut.

      SST
      09330-00021
    3. A01X7BVE01

      Using SST, remove the companion flange.

      SST
      09950-40011   ( 09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04051, 09957-04010, 09958-04011 )

    4. Remove the O-ring from the companion flange.

  10. REMOVE TRANSFER CASE REAR OIL SEAL

    Click here

  11. REMOVE NO. 1 TRANSFER CASE PLUG


    1. A01X5JX

      Remove the plug, compression spring and pin.

  12. REMOVE TRANSFER CASE PLUG


    1. A01X4QB

      Using a 6 mm hexagon wrench, remove the plug.

  13. REMOVE REAR TRANSFER CASE ASSEMBLY


    1. A01X0M2

      Remove the 14 bolts.

    2. Remove the rear transfer case.

      Tech Tips

      If necessary, tap the rear transfer case with a plastic-faced hammer to remove it.

  14. REMOVE FRONT TRANSFER OUTPUT SHAFT NEEDLE ROLLER BEARING

    A01X978E06
    *1 Needle Roller Bearing
    *2 Spacer

    1. Remove the needle roller bearing and spacer from the output shaft.

  15. REMOVE NO. 2 TRANSFER GEAR SHIFT FORK


    1. A01X6Y3

      Using 2 screwdrivers and a hammer, tap out the 4 shift fork shaft snap rings.

    2. A01X6G3

      Remove the bolt. Then remove the No. 2 gear shift fork together with the high and low clutch sleeve from the shift actuator.

  16. REMOVE TRANSFER SHIFT ACTUATOR ASSEMBLY


    1. A01XBOT

      Remove the No. 1 gear shift fork bolt.

    2. A01X23L

      Remove the 3 bolts.

    3. A01WZV2E02
      *1 Shift Actuator
      *2 No. 1 Transfer Gear Shift Fork

      Remove the shift actuator and No. 1 gear shift fork from the rear transfer case.

      Note

      Take care not to drop the No. 1 gear shift fork.

    4. A01XARWE05
      *1 O-Ring

      Remove the O-ring from the shift actuator.

  17. REMOVE REAR TRANSFER OUTPUT SHAFT ASSEMBLY


    1. A01X94G

      Using a snap ring expander, expand the snap ring as shown in the illustration.

    2. A01X6KA

      Using a plastic-faced hammer, carefully tap the rear transfer case, and remove the output shaft together with the drive chain and driven sprocket.

    3. Remove the output shaft and driven sprocket from the drive chain.

      Note

      Do not drop the output shaft washers.

    4. A01X8BC

      Using a snap ring expander, remove the snap ring from the rear transfer case.

  18. REMOVE FRONT DRIVE CLUTCH SLEEVE

    A01X26Q

    1. Remove the clutch sleeve from the output shaft.

  19. REMOVE SIDE GEAR SHAFT HOLDER BEARING


    1. A01XAFZ

      Using a screwdriver, remove the snap ring.

    2. A01X6Y9E01

      Using SST, remove the bearing.

      SST
      09308-00010

  20. REMOVE TRANSFER OIL SEPARATOR SUB-ASSEMBLY


    1. A01X266

      Remove the 3 bolts and oil separator.

    2. Remove the O-ring from the oil separator.

  21. REMOVE TRANSFER CASE MAGNET

    A01X8EH

    1. Remove the magnet from the oil separator.

  22. REMOVE TRANSFER INPUT SHAFT ASSEMBLY


    1. A01X483

      Using a 14 mm hexagon wrench, remove the 2 case plugs from the front transfer case.

    2. A01X5FI

      Using a snap ring expander, expand the snap ring as shown in the illustration. Then remove the input shaft from the front transfer case.

  23. REMOVE TRANSFER LOW PLANETARY RING GEAR


    1. A01X0WQ

      Using a screwdriver, remove the snap ring. Then remove the low planetary ring gear from the front transfer case.

    2. A01X7YX

      Using a snap ring expander, remove the snap ring from the front transfer case.

  24. REMOVE TRANSFER DRIVEN SPROCKET BEARING


    1. A01XA1F

      Using a screwdriver, remove the snap ring. Then remove the bearing from the front transfer case.

  25. REMOVE NO. 1 SYNCHRONIZER RING (for Manual Transmission)

    A01X89S

    1. Remove the synchronizer ring from the input shaft.

  26. REMOVE NO. 1 TRANSFER INPUT SHAFT SEAL RING


    1. A01X8Y7E01
      *1 Seal Ring

      Remove the seal ring from the input shaft.

  27. REMOVE TRANSFER INPUT SHAFT BEARING


    1. A01WZXK

      Using a snap ring expander, remove the snap ring.

    2. A01X8CNE01

      Using SST and a press, press out the bearing.

      SST
      09555-55010
      09950-60010   ( 09951-00490 )
      09950-70010   ( 09951-07100 )

      Note

      Be careful not to drop or damage the input shaft, low planetary gear and low planetary gear bearings.

      Tech Tips

      When the bearing is removed, the input shaft, low planetary gear, and 2 low planetary gear bearings will come off.

  28. REMOVE TRANSFER INPUT SHAFT BIMETAL FORMED BUSH


    1. A01X2SZE01

      Using SST, remove the bush.

      SST
      09387-00041   ( 09387-01021, 09387-01030, 09387-01040 )

  29. REMOVE TRANSFER INPUT SHAFT PLUG


    1. A01X2UBE01

      Using SST and a hammer, tap out the input shaft plug.

      SST
      09950-70010   ( 09951-07150 )
      09950-60010   ( 09951-00300 )

  30. REMOVE TRANSFER OUTPUT SHAFT WASHER


    1. A01X9C2

      Remove the 2 output shaft washers from the output shaft.

  31. REMOVE NO. 1 TRANSFER OUTPUT SHAFT SPACER


    1. A01X09J

      Using 2 screwdrivers and a hammer, tap out the snap ring.

    2. A01XBPM

      Remove the output shaft spacer from the output shaft.

    3. A01X2TK

      Remove the seal ring from the output shaft spacer.

    4. A01XAANE01
      *1 Straight Pin

      Remove the straight pin from the output shaft.

  32. REMOVE CENTER DIFFERENTIAL CASE


    1. A01X98O

      Remove the center differential case from the output shaft.

    2. A01WZUZ

      for Manual Transmission:

      Using a snap ring expander, remove the snap ring.

    3. A01X2MB

      for Manual Transmission:

      Remove the synchromesh shifting key spring and No. 2 synchromesh shifting keys from the center differential case.

    4. A01X871E04

      Using SST, remove the needle roller bearing.

      SST
      09308-00010
    5. A01X0IIE01

      Using SST, remove the needle roller bearing.

      SST
      09387-00041   ( 09387-01021, 09387-01030, 09387-01040 )

  33. REMOVE TRANSFER OUTPUT SHAFT SPACER


    1. A01XC0C

      Using 2 screwdrivers and a hammer, tap out the snap ring.

    2. A01X729

      Remove the output shaft spacer from the output shaft.

    3. A01X0UJE01
      *1 Straight Pin

      Remove the straight pin from the output shaft.

  34. REMOVE TRANSFER DRIVE SPROCKET SUB-ASSEMBLY


    1. A01X95N

      Remove the drive sprocket from the output shaft.

  35. REMOVE TRANSFER DRIVE SPROCKET BEARING


    1. A01X7W6

      Remove the bearing from the output shaft.

  36. REMOVE REAR TRANSFER OUTPUT SHAFT


    1. A01XBSJE01

      Using SST and a press, press out the bearing.

      SST
      09527-10011

      Note

      Be careful not to drop or damage the output shaft.

    2. A01XBPL

      Remove the needle roller bearing from the output shaft.