TRANSFER ASSEMBLY DISASSEMBLY

PROCEDURE


  1. REMOVE PROPELLER SHAFT HEAT INSULATOR BRACKET SUB-ASSEMBLY


    1. A01WS7V

      Remove the bolt and bracket.

  2. REMOVE TRANSFER OIL PUMP PLATE


    1. A01WUZ7

      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. A01WPQW

      Remove the transfer oil seal ring from the input shaft.

    4. A01WRVAE08
      *1 Oil Pump Drive Rotor

      Remove the oil pump drive rotor from the input shaft.

  3. REMOVE TRANSFER CASE STRAIGHT PIN


    1. A01WU0ME06
      *1 Transfer Case Straight Pin

      Remove the 2 straight pins.

      Note

      Do not drop the straight pins.

  4. REMOVE TRANSFER CASE PLUG


    1. A01WQJP

      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. A01WVH7

      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. A01WVEYE06

      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. A01WTG0E03

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

      SST
      09330-00021
    3. A01WS6OE01

      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. A01WWU2E01

      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. A01WPFUE01

      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. A01WW2SE05

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

      SST
      09330-00021
    3. A01WQ5ZE03

      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. A01WRV7

      Remove the plug, compression spring and pin.

  12. REMOVE TRANSFER CASE PLUG


    1. A01WTAQ

      Using a 6 mm hexagon wrench, remove the plug.

  13. REMOVE REAR TRANSFER CASE ASSEMBLY


    1. A01WS0L

      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

    A01WSQJE07
    *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. A01WR3H

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

    2. A01WPXW

      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. A01WPGR

      Remove the No. 1 gear shift fork bolt.

    2. A01WRKX

      Remove the 3 bolts.

    3. A01WVZQE04
      *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. A01WU2SE06
      *1 O-Ring

      Remove the O-ring from the shift actuator.

  17. REMOVE REAR TRANSFER OUTPUT SHAFT ASSEMBLY


    1. A01WQXA

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

    2. A01WPGI

      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. A01WW9C

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

  18. REMOVE FRONT DRIVE CLUTCH SLEEVE

    A01WVPN

    1. Remove the clutch sleeve from the output shaft.

  19. REMOVE SIDE GEAR SHAFT HOLDER BEARING


    1. A01WTRJ

      Using a screwdriver, remove the snap ring.

    2. A01WRAEE01

      Using SST, remove the bearing.

      SST
      09308-00010

  20. REMOVE TRANSFER OIL SEPARATOR SUB-ASSEMBLY


    1. A01WQB3

      Remove the 3 bolts and oil separator.

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

  21. REMOVE TRANSFER CASE MAGNET

    A01WQPA

    1. Remove the magnet from the oil separator.

  22. REMOVE TRANSFER INPUT SHAFT ASSEMBLY


    1. A01WUSS

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

    2. A01WRVY

      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. A01WRT7

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

    2. A01WVXK

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

  24. REMOVE TRANSFER DRIVEN SPROCKET BEARING


    1. A01WPBB

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

  25. REMOVE NO. 1 TRANSFER INPUT SHAFT SEAL RING


    1. A01WVBSE01
      *1 Seal Ring

      Remove the seal ring from the input shaft.

  26. REMOVE TRANSFER INPUT SHAFT BEARING


    1. A01WWY5

      Using a snap ring expander, remove the snap ring.

    2. A01WS0NE01

      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.

  27. REMOVE TRANSFER INPUT SHAFT BIMETAL FORMED BUSH


    1. A01WR6ME01

      Using SST, remove the bush.

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

  28. REMOVE TRANSFER INPUT SHAFT PLUG


    1. A01WTSFE02

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

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

  29. REMOVE TRANSFER OUTPUT SHAFT WASHER


    1. A01WQZC

      Remove the 2 output shaft washers from the output shaft.

  30. REMOVE NO. 1 TRANSFER OUTPUT SHAFT SPACER


    1. A01WVY6

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

    2. A01WWPZ

      Remove the output shaft spacer from the output shaft.

    3. A01WSAU

      Remove the seal ring from the output shaft spacer.

    4. A01WU9OE01
      *1 Straight Pin

      Remove the straight pin from the output shaft.

  31. REMOVE CENTER DIFFERENTIAL CASE


    1. A01WUHU

      Remove the center differential case from the output shaft.

    2. A01WTAGE05

      Using SST, remove the needle roller bearing.

      SST
      09308-00010
    3. A01WQ72E01

      Using SST, remove the needle roller bearing.

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

  32. REMOVE TRANSFER OUTPUT SHAFT SPACER


    1. A01WPIG

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

    2. A01WQRJ

      Remove the output shaft spacer from the output shaft.

    3. A01WWFNE02
      *1 Straight Pin

      Remove the straight pin from the output shaft.

  33. REMOVE TRANSFER DRIVE SPROCKET SUB-ASSEMBLY


    1. A01WSMX

      Remove the drive sprocket from the output shaft.

  34. REMOVE TRANSFER DRIVE SPROCKET BEARING


    1. A01WVTN

      Remove the bearing from the output shaft.

  35. REMOVE REAR TRANSFER OUTPUT SHAFT


    1. A01WQEUE02

      Using SST and a press, press out the bearing.

      SST
      09527-10011

      Note

      Be careful not to drop or damage the output shaft.

    2. A01WU2I

      Remove the needle roller bearing from the output shaft.