TRANSFER ASSEMBLY DISASSEMBLY

PROCEDURE


  1. REMOVE HOSE


    1. Detach the clamp and remove the hose.

  2. REMOVE TRANSFER BEARING RETAINER SUB-ASSEMBLY RH


    1. Remove the 5 bolts and transfer bearing retainer sub-assembly RH.

      Tech Tips

      If necessary, tap the transfer bearing retainer sub-assembly RH with a plastic-faced hammer to remove it.

    2. for RA61F:

      Remove the O-ring from the transfer bearing retainer sub-assembly RH.

  3. REMOVE TRANSFER BEARING RETAINER OIL SEAL RH


    1. for A750F, AC60F, G52F, R150F:

      Using a screwdriver and hammer, remove the transfer bearing retainer oil seal RH from the transfer bearing retainer sub-assembly RH.

    2. for RA61F:

      Using a screwdriver and hammer, remove the 2 transfer bearing retainer oil seals RH from the transfer bearing retainer sub-assembly RH.

  4. REMOVE TRANSFER CASE COVER SUB-ASSEMBLY


    1. Remove the 4 bolts and transfer case cover sub-assembly.

  5. REMOVE BREATHER OIL DEFLECTOR


    1. Remove the breather oil deflector.

  6. REMOVE FRONT OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY


    1. Using a chisel and hammer, loosen the staked part of the lock nut.

    2. A01XDY1E01
      Text in Illustration
      *a Turn
      *b Hold

      Using SST to hold the front output shaft companion flange sub-assembly, remove the lock nut.

      SST
      09330-00021
    3. A01XLEHE01

      Using SST, remove the companion flange.

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

  7. REMOVE FRONT TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL


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

      Note

      Be careful not to damage the oil seal and companion flange contact surfaces.

  8. REMOVE TRANSFER CASE FRONT OIL SEAL

    Click here

  9. REMOVE REAR OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY


    1. Using a chisel and hammer, loosen the staked part of the lock nut.

    2. A01XF09E01

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

      SST
      09330-00021
    3. A01XHOZE01

      Using SST, remove the companion flange.

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

  10. REMOVE REAR TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL


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

      Note

      Be careful not to damage the oil seal and companion flange contact surfaces.

  11. REMOVE TRANSFER CASE REAR OIL SEAL

    Click here

  12. REMOVE TRANSFER EXTENSION HOUSING SUB-ASSEMBLY


    1. Remove the 5 bolts and extension housing.

      Tech Tips

      If necessary, tap the extension housing with a plastic-faced hammer to remove it.

  13. REMOVE TRANSFER OUTPUT SHAFT WASHER


    1. Remove the 2 washers.

  14. REMOVE COLLAR


    1. Remove the collar.

  15. REMOVE REAR TRANSFER CASE


    1. Remove the 12 bolts and clamp.

    2. Remove the rear transfer case.

      Tech Tips

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

  16. REMOVE NO. 2 TRANSFER GEAR SHIFT FORK SUB-ASSEMBLY WITH TRANSFER HIGH AND LOW CLUTCH SLEEVE


    1. A01XGIG

      Remove the bolt, No. 2 gear shift fork, and high and low clutch sleeve.

  17. REMOVE CENTER DIFFERENTIAL LOCK FORK SUB-ASSEMBLY WITH FRONT DRIVE CLUTCH SLEEVE


    1. A01XFCS

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

    2. A01XI9J

      Remove the bolt, center differential lock fork and front drive clutch sleeve.

  18. REMOVE REAR OUTPUT SHAFT SUB-ASSEMBLY, FRONT DRIVE CHAIN AND DRIVEN SPROCKET SUB-ASSEMBLY


    1. Mount the rear transfer case in a vise.

    2. Using a snap ring expander, remove the snap ring.

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

    4. Remove the rear output shaft, front drive chain and driven sprocket.

  19. REMOVE TRANSFER DRIVEN SPROCKET BEARING


    1. A01XKPHE01

      Using SST and a press, remove the driven sprocket bearing.

      SST
      09555-55010

      Note

      Be careful not to drop or damage the driven sprocket.

  20. REMOVE TRANSFER INPUT GEAR RADIAL BALL BEARING


    1. A01XK3DE01

      Using SST and a press, remove the transfer input gear radial ball bearing.

      SST
      09555-55010

      Note

      Be careful not to drop or damage the driven sprocket.

  21. REMOVE TRANSFER SHIFT ACTUATOR ASSEMBLY


    1. A01XEDR

      Using 2 screwdrivers and a hammer, tap off the 2 snap rings.

    2. Remove the 3 bolts and transfer shift actuator assembly.

    3. A01XM4A

      Remove the O-ring from the transfer shift actuator assembly.

  22. REMOVE FILLER PLUG


    1. Remove the filler plug and gasket.

  23. REMOVE DRAIN PLUG


    1. Remove the drain plug and gasket.

  24. REMOVE TRANSFER OIL SEPARATOR SUB-ASSEMBLY


    1. Remove the 3 bolts and oil separator.

  25. REMOVE TRANSFER CASE MAGNET

  26. REMOVE TRANSFER OIL PUMP BODY SUB-ASSEMBLY


    1. Remove the 3 bolts and oil pump body.

  27. REMOVE TRANSFER OIL PUMP BODY O-RING

    A01XG23

    1. Using a screwdriver, remove the oil pump body O-ring.

      Note

      Be careful not to damage the oil pump body.

  28. REMOVE TRANSFER OIL PUMP GEAR


    1. Remove the transfer oil pump gear.

  29. REMOVE LOW PLANETARY GEAR ASSEMBLY WITH TRANSFER INPUT SHAFT SUB-ASSEMBLY


    1. A01XM91

      Using a snap ring expander, remove the snap ring.

    2. Remove the low planetary gear together with the input shaft.

  30. REMOVE TRANSFER OUTPUT SHAFT SPACER


    1. Remove the transfer output shaft spacer.

  31. REMOVE TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING


    1. Remove the needle roller bearing.

  32. REMOVE TRANSFER INPUT GEAR STOPPER SHAFT SNAP RING


    1. A01XDW9

      Using a snap ring expander, remove the snap ring.

  33. REMOVE TRANSFER INPUT GEAR STOPPER


    1. Remove the input gear stopper.

  34. REMOVE TRANSFER INPUT GEAR STOPPER BALL


    1. Remove the ball.

  35. REMOVE MANUAL TRANSFER PLANETARY CARRIER WASHER


    1. Remove the washer.

  36. REMOVE TRANSFER INPUT SHAFT


    1. Remove the transfer input shaft.

  37. REMOVE NO. 1 TRANSFER THRUST BEARING RACE


    1. Remove the thrust bearing race.

  38. REMOVE TRANSFER LOW PLANETARY GEAR THRUST BEARING


    1. Remove the bearing.

  39. REMOVE NO. 1 TRANSFER INPUT SHAFT SEAL RING


    1. A01XFRV

      Remove the 2 seal rings.

  40. REMOVE TRANSFER INPUT SHAFT BEARING


    1. Using a snap ring expander, remove the snap ring.

    2. A01XHX8E07

      Using SST and a press, remove the input shaft bearing.

      SST
      09555-55010
      09950-70010   ( 09951-07150 )
      09950-60020   ( 09951-00750 )

      Note

      Be careful not to drop or damage the low planetary gear.

  41. REMOVE TRANSFER LOW PLANETARY GEAR SPLINE PIECE


    1. A01XJ7G

      Using a screwdriver, remove the snap ring.

    2. Remove the low planetary gear spline piece.

  42. REMOVE TRANSFER LOW PLANETARY GEAR BEARING


    1. A01XKPBE09

      Using SST, remove the low planetary gear bearing.

      SST
      09612-65014   ( 09612-01030, 09612-01050 )

      Note

      Make sure SST fits securely in the space between the bearing and low planetary gear.

  43. REMOVE NO. 2 TRANSFER OUTPUT SHAFT SPACER


    1. Using a snap ring expander, remove the snap ring.

    2. Remove the spacer.

  44. REMOVE TRANSFER OUTPUT SHAFT SPACER BALL


    1. Remove the ball.

  45. REMOVE CENTER DIFFERENTIAL CASE


    1. Remove the center differential case.

  46. REMOVE TRANSFER CLUTCH HUB


    1. Remove the transfer clutch hub.

  47. REMOVE TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING


    1. Remove the needle roller bearing.

  48. REMOVE TRANSFER OUTPUT SHAFT PLATE WASHER


    1. Remove the washer.

  49. REMOVE REAR TRANSFER OUTPUT SHAFT RADIAL BALL BEARING


    1. A01XMBFE01

      Using SST and a press, remove the bearing.

      SST
      09555-55010

  50. REMOVE NO. 1 TRANSFER OUTPUT SHAFT SPACER


    1. Remove the output shaft spacer.

  51. REMOVE TRANSFER DRIVE SPROCKET SUB-ASSEMBLY


    1. Remove the transfer drive sprocket.

  52. REMOVE TRANSFER DRIVE SPROCKET BEARING


    1. Remove the bearing.

  53. REMOVE TRANSFER OUTPUT SHAFT PLATE WASHER


    1. Remove the washer.

  54. REMOVE TRANSFER CASE PLUG


    1. Remove the transfer case plug.

  55. REMOVE COMPRESSION SPRING


    1. Remove the spring.

  56. REMOVE PIN


    1. Remove the pin.

  57. REMOVE TRANSFER LOW PLANETARY RING GEAR


    1. A01XF7Z

      Using a screwdriver, remove the snap ring.

    2. Remove the low planetary ring gear from the front transfer case.