TRANSFER ASSEMBLY DISASSEMBLY

PROCEDURE


  1. REMOVE ACTUATOR BREATHER HOSE


    1. B003N06

      Disconnect the connection to the transfer shift actuator assembly, detach the 2 clamps, and then remove the actuator breather hose.

  2. REMOVE TRANSFER CASE COVER SUB-ASSEMBLY


    1. B003OOE

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

    2. B003J2Q

      Remove the breather oil deflector.

  3. REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY (for Front Side)


    1. Using a chisel and hammer, loosen the staked part of the transfer output shaft companion flange nut.

      Note


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

      • Do not damage the threads of the driven sprocket.

    2. B003QVVC01
      *a Turn
      *b Hold

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

      SST
      09330-00021
    3. B003LSYC01
      *a Turn
      *b Hold

      Using SST, remove the output shaft companion flange sub-assembly.

      SST
      09950-40011   ( 09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04031, 09957-04010, 09958-04011 )

      Note

      Apply a lubricant to the threads and end of SST.

    4. B003MSLN01

      Using SST and hammer, remove the transfer output shaft companion flange oil seal.

      SST
      09950-60010   ( 09951-00220, 09951-00290, 09952-06010 )
      09950-70010   ( 09951-07100 )

      Note

      Be careful not to damage the transfer output shaft companion flange oil seal and output shaft companion flange sub-assembly contact surfaces.

  4. REMOVE TRANSFER CASE OIL SEAL

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  5. REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY (for Rear Side)


    1. Using a chisel and hammer, loosen the staked part of the transfer output shaft companion flange nut.

      Note


      • Completely loosen the staked part of the transfer output shaft companion flange nut when removing it.

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

    2. B003MZ1C01
      *a Turn
      *b Hold

      Using SST to hold the output shaft companion flange sub-assembly, remove the transfer output shaft companion flange nut and transfer output shaft O-ring.

      SST
      09330-00021
    3. B003NI8C01
      *a Turn
      *b Hold

      Using SST, remove the output shaft companion flange sub-assembly.

      SST
      09950-40011   ( 09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04031, 09957-04010, 09958-04011 )

      Note

      Apply a lubricant to the threads and end of SST.

  6. REMOVE TRANSFER EXTENSION HOUSING TYPE T OIL SEAL

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  7. REMOVE TRANSFER EXTENSION HOUSING


    1. B003NC7

      Remove the 5 bolts and transfer extension housing.

      Tech Tips

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

  8. REMOVE TRANSFER OUTPUT SHAFT WASHER


    1. B003P68C01
      *1 Transfer Output Shaft Washer
      *2 No. 2 Transfer Output Shaft Spacer

      Remove the 2 transfer output shaft washers.

    2. Remove the No. 2 transfer output shaft spacer.

  9. REMOVE NO. 1 TRANSFER CASE PLUG


    1. B003S3PC01
      *1 No. 1 Transfer Case Plug (Filler Plug)
      *2 No. 1 Transfer Case Gasket
      *3 Transfer Drain Plug
      *4 Transfer Drain Plug Gasket

      Remove the No. 1 transfer case plug (filler plug) and No. 1 transfer case gasket.

    2. Remove the transfer drain plug and transfer drain plug gasket.

  10. REMOVE REAR TRANSFER CASE


    1. B003MHBC01
      *1 Bracket

      Remove the 12 bolts and 4 brackets.

    2. Remove the rear transfer case.

      Tech Tips

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

  11. REMOVE TRANSFER OIL SEPARATOR SUB-ASSEMBLY


    1. B003O7R

      Remove the 3 bolts and transfer oil separator sub-assembly.

    2. Remove the transfer case magnet.

  12. REMOVE TRANSFER OIL PUMP BODY SUB-ASSEMBLY


    1. B003L6Q

      Remove the 3 bolts and transfer oil pump body sub-assembly.

    2. B003R55C01
      *a Protective Tape

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

      Note

      Be careful not to damage the transfer oil pump body sub-assembly.

      Tech Tips

      Tape the screwdriver tip before use.

    3. B003N7X

      Remove the transfer oil pump gear.

  13. REMOVE TRANSFER FRONT BEARING RETAINER SUB-ASSEMBLY


    1. B003OT6

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

      Tech Tips

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

    2. for RC60F / RC61F:

      Remove the O-ring.

  14. REMOVE TRANSFER FRONT BEARING TYPE T OIL SEAL


    1. B003NSOC01
      *a Protective Tape

      for AC60F, R151F:

      Using a screwdriver and hammer, remove the transfer front bearing type T oil seal.

      Note

      Be careful not to damage the transfer front bearing type T oil seal and transfer front bearing retainer sub-assembly contact surfaces.

      Tech Tips

      Tape the screwdriver tip before use.

    2. for RC60F / RC61F:

      Using a screwdriver and hammer, remove the 2 transfer front bearing type T oil seals.

      Note

      Be careful not to damage the transfer front bearing type T oil seal and transfer front bearing retainer sub-assembly contact surfaces.

      Tech Tips

      Tape the screwdriver tip before use.

  15. REMOVE TRANSFER LOW PLANETARY GEAR ASSEMBLY


    1. B003LDY

      Using a snap ring expander, remove the transfer low planetary gear bearing shaft snap ring.

    2. B003QM9

      Remove the transfer low planetary gear assembly with the transfer input shaft.

  16. REMOVE TRANSFER CASE PLUG


    1. B003PR7C01
      *1 Transfer Case Plug
      *2 Transfer Case Compression Spring
      *3 Pin

      Remove the transfer case plug, transfer case compression spring and pin.

  17. REMOVE TRANSFER LOW PLANETARY RING GEAR


    1. B003J4QC01
      *a Protective Tape

      Using a screwdriver, remove the transfer low planetary ring gear hole snap ring.

      Note

      Be careful not to damage the front transfer case.

      Tech Tips

      Tape the screwdriver tip before use.

    2. Remove the transfer low planetary ring gear.

  18. REMOVE TRANSFER LOW PLANETARY GEAR SPLINE PIECE


    1. B003LE5C01
      *a Protective Tape

      Using a screwdriver, remove the transfer low planetary gear shaft snap ring.

      Note

      Be careful not to damage the transfer low planetary gear assembly.

      Tech Tips

      Tape the screwdriver tip before use.

    2. B003OD2

      Remove the transfer low planetary gear spline piece.

    3. B003JAJ

      Remove the transfer output shaft front needle roller bearing.

  19. REMOVE TRANSFER INPUT SHAFT


    1. B003RUQ

      Using a snap ring expander, remove the transfer input gear stopper shaft snap ring.

    2. B003RUKC01
      *1 Transfer Input Gear Stopper
      *2 Transfer Input Gear Stopper Ball
      *3 Manual Transfer Planetary Carrier Washer

      Remove the transfer input gear stopper and transfer input gear stopper ball.

    3. Remove the manual transfer planetary carrier washer.

    4. B003RV2C01
      *1 Transfer Input Shaft
      *2 Transfer Low Planetary Gear Bearing
      *3 No. 1 Transfer Thrust Bearing Race

      Remove the transfer input shaft, transfer low planetary gear bearing and No. 1 transfer thrust bearing race.

  20. REMOVE NO. 1 TRANSFER INPUT SHAFT SEAL RING


    1. B003OSS

      Remove the 2 No. 1 transfer input shaft seal rings.

  21. REMOVE TRANSFER INPUT SHAFT BEARING


    1. B003QT7

      Using a snap ring expander, remove the transfer input bearing shaft snap ring.

    2. B003PRQC01
      *a Turn
      *b Hold

      Using SST, remove the transfer input shaft bearing.

      SST
      09555-55010
      09950-00030
      09950-60020   ( 09951-00630 )

      Note


      • Be careful not to damage the transfer low planetary gear assembly.

      • Apply a lubricant to the threads and end of SST.

  22. REMOVE TRANSFER LOW PLANETARY GEAR BEARING


    1. B003P5WC01
      *a Turn
      *b Hold

      Using SST, remove the transfer low planetary gear bearing.

      SST
      09527-10011
      09612-65014   ( 09612-01050, 09612-01060 )

      Note

      Hook SST securely between the bearing and transfer low planetary gear.

  23. REMOVE TRANSFER FRONT DRIVE SHIFT FORK SHAFT

    Note


    • When using a vise, place aluminum plates between the part and vise.

    • When using a vise, do not overtighten it.


    1. B003P60C01
      *1 Shift Detent Ball Spring Plug
      *2 Shift Detent Ball Compression Spring
      *3 Shift Detent Ball

      Using a 6 mm hexagon wrench, remove the 2 shift detent ball spring plugs.

    2. Using a magnet hand, remove the 2 shift detent ball compression springs and 2 shift detent balls.

    3. B003K0A

      Using 2 screwdrivers and a hammer, remove the 2 transfer gear shift fork shaft snap rings.

      Tech Tips

      Use a piece of cloth to prevent the transfer gear shift fork shaft snap rings from flying off.

    4. B003O9E

      Remove the bolt and transfer shift shaft stopper.

    5. B003PH6C01
      *1 Transfer Front Drive Shift Fork Shaft
      *2 No. 1 Transfer Gear Shift Fork
      *3 No. 2 Transfer Gear Shift Fork

      To remove the transfer front drive shift fork shaft, shift the No. 1 transfer gear shift fork and No. 2 transfer gear shift fork to the positions shown in the illustration.

    6. Remove the transfer front drive shift fork shaft.

    7. B003LTU

      Using a magnet hand, remove the 2 shift interlock pin or rollers.

  24. REMOVE REAR TRANSFER OUTPUT SHAFT, TRANSFER FRONT DRIVE CHAIN, TRANSFER DRIVEN SPROCKET

    Note


    • When using a vise, place aluminum plates between the part and vise.

    • When using a vise, do not overtighten it.


    1. B003QWE

      Using 2 screwdrivers and a hammer, remove the transfer gear shift fork shaft snap ring.

      Tech Tips


      • Use a piece of cloth to prevent the transfer gear shift fork shaft snap ring from flying off.

      • Remove only the transfer gear shift fork shaft snap ring on the front side of the transfer shift actuator shaft.

    2. B003PQX

      Using a snap ring expander, remove the transfer output shaft shaft snap ring.

    3. B003LJ6

      Using a plastic-faced hammer, carefully tap the rear transfer case, and remove the transfer output shaft rear, transfer driven sprocket and transfer front drive chain with the No. 1 transfer gear shift fork and No. 2 transfer gear shift fork.

  25. REMOVE TRANSFER SHIFT ACTUATOR ASSEMBLY


    1. B003J84

      Using 2 screwdrivers and a hammer, remove the transfer gear shift fork shaft snap ring.

      Tech Tips

      Use a piece of cloth to prevent the transfer gear shift fork shaft snap ring from flying off.

    2. B003L3O

      Remove the 3 bolts and transfer shift actuator assembly.

  26. REMOVE TRANSFER DRIVEN SPROCKET BEARING


    1. B003NW3N01

      for Front Side:

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

      SST
      09555-55010
      09950-60010   ( 09951-00210 )
      09950-70010   ( 09951-07100 )

      Note

      Be careful not to drop or damage the driven sprocket.

    2. B003PUBN01

      for Rear Side:

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

      SST
      09555-55010
      09950-60010   ( 09951-00270 )
      09950-70010   ( 09951-07100 )

      Note

      Be careful not to drop or damage the driven sprocket.

  27. REMOVE TRANSFER CLUTCH HUB


    1. Remove the transfer high and low clutch sleeve.

    2. B003OYS

      Using a snap ring expander, remove the transfer clutch hub shaft snap ring.

    3. B003KCVN01

      Using SST and a press, remove the transfer clutch hub.

      SST
      09527-10011

      Note

      Be careful not to drop or damage the rear transfer output shaft.

  28. REMOVE TRANSFER DRIVE SPROCKET SUB-ASSEMBLY


    1. B003KZWN01

      Using SST and a press, remove the rear transfer output shaft radial ball bearing.

      SST
      09555-55010

      Note

      Be careful not to drop or damage the rear transfer output shaft.

    2. B003KXJC01
      *1 No. 1 Transfer Output Shaft Spacer
      *2 Needle Roller Bearing
      *3 Transfer Drive Sprocket Sub-assembly

      Remove the No. 1 transfer output shaft spacer.

    3. Remove the needle roller bearing.

    4. Remove the transfer drive sprocket sub-assembly.

  29. REMOVE TRANSFER SYNCHRONIZER RING SET


    1. B003OF7

      Remove the transfer synchronizer ring set.

  30. REMOVE FRONT DRIVE CLUTCH SLEEVE


    1. B003P2SC01
      *1 Front Drive Clutch Sleeve
      *2 Transfer Synchromesh Shifting Key Spring
      *3 No. 1 Synchromesh Shifting Key

      Remove the front drive clutch sleeve.

      Note

      Be careful not to drop the 3 No. 1 synchromesh shifting keys.

    2. Remove the 2 transfer synchromesh shifting key springs and 3 No. 1 synchromesh shifting keys.

  31. REMOVE TRANSFER DRIVE CLUTCH HUB


    1. B003OBEN01

      Using SST and a press, remove the transfer drive clutch hub.

      SST
      09527-10011

      Note

      Be careful not to drop or damage the rear transfer output shaft.