TRANSFER ASSEMBLY DISASSEMBLY

PROCEDURE


  1. REMOVE DYNAMIC DAMPER


    1. A000U0Y

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

  2. REMOVE TRANSFER CASE PLUG


    1. A000YKW

      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. A000X47

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

  4. REMOVE TRANSFER DRAIN PLUG


    1. A000TGG

      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. A000WVN

      Remove the breather plug from the front transfer case.

  6. REMOVE NO. 2 TRANSFER CASE PLUG


    1. A000WD2

      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. A000VYEE01

      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. A000VT5E01
      *1 Hold
      *2 Turn

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

  8. REMOVE DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY


    1. A000U8BE01

      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. A000ZKYE04
      *1 Turn
      *2 Hold

      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. A000UCPE08
      *1 Turn
      *2 Hold

      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. A000WGEE01

      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. A000UPG

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

  11. REMOVE TRANSFER EXTENSION HOUSING


    1. A001034

      Remove the 11 bolts and bracket.

    2. A000YA3

      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. A00100CE04
      *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. A000YVCE01

      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. A00104T

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

  15. REMOVE DIFFERENTIAL CASE NEEDLE ROLLER BEARING


    1. A000T8W

      Remove the bearing from the No. 1 differential case.

  16. REMOVE NO. 2 TRANSFER THRUST BEARING RACE


    1. A000V2E

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

  17. REMOVE TRANSFER OUTPUT SHAFT SHIM


    1. A000Z03

      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. A00105YE01
      *1 Turn
      *2 Hold

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

      SST
      09950-00020
      09950-00030

  20. REMOVE BREATHER OIL DEFLECTOR


    1. A000V6S

      Remove the 2 bolts and oil deflector.

  21. REMOVE TRANSFER INPUT GEAR STOPPER SHAFT SNAP RING


    1. A000U4A

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

  22. REMOVE TRANSFER INPUT GEAR STOPPER


    1. A000ZXL

      Remove the gear stopper from the input shaft.

  23. REMOVE REAR TRANSFER CASE


    1. A000W7U

      Remove the 7 bolts and rear transfer case.

  24. REMOVE TRANSFER IDLER GEAR ASSEMBLY


    1. A000Y8V

      Remove the idler gear from the front transfer case.

  25. REMOVE TRANSFER OIL PUMP DRIVE SHAFT


    1. A000V1M

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

  26. REMOVE TRANSFER COUNTER GEAR ASSEMBLY


    1. A000XT3

      Remove the counter gear from the front transfer case.

  27. REMOVE TRANSFER FRONT DRIVE GEAR ASSEMBLY


    1. A000U3P

      Remove the drive gear from the front transfer case.

  28. REMOVE TRANSFER FRONT DRIVE GEAR PIN


    1. A000YJH

      Remove the drive gear pin from the front transfer case.

  29. REMOVE TRANSFER INPUT SHAFT


    1. A000YRH

      Remove the input shaft from the drive gear.

  30. REMOVE TRANSFER OIL SEAL RING


    1. A000TTQ

      Remove the oil seal ring from the input shaft.

  31. REMOVE DRIVE PINION COMPANION FLANGE OIL SEAL


    1. A000VLTE05
      *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. A000YCCE01
      *1 Turn
      *2 Hold

      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. A000W5IE01
      *1 Turn
      *2 Hold

      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. A000UK7E01
      *1 Hold
      *2 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. A000Y90E04
      *1 Hold
      *2 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. A000Y9L

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

  35. REMOVE NO. 1 TRANSFER OIL STRAINER


    1. A000WVD

      Remove the oil strainer from the front transfer case.

  36. REMOVE TRANSFER OIL COOLER RELIEF VALVE


    1. A000V9X

      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. A000Z97

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

  37. REMOVE TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL


    1. A000ZSFE01
      *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. A000W2UE06
      *1 Turn
      *2 Hold

      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. A000ZP5E06
      *1 Turn
      *2 Hold

      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. A000XCWE01
      *1 Hold
      *2 Turn

      for Front Transfer Case Side:


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

        SST
        09612-65014   ( 09612-01020 )
    2. A000X8QE04
      *1 Turn
      *2 Hold

      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. A000VCY

      Remove the oil seal ring from the sleeve.

  42. REMOVE TRANSFER FRONT CASE OIL SEAL


    1. A000Y41E03
      *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. A000ZUXE05
      *1 Roller
      *2 Roller Cage

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

    2. A000Z7W

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

    3. A000VV8E05
      *1 Turn
      *2 Hold

      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. A000ZFI

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

    2. A001041E04

      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.