TRANSFER ASSEMBLY DISASSEMBLY

REMOVE PROPELLER SHAFT HEAT INSULATOR BRACKET SUB-ASSEMBLY

1. 

   Remove the bolt and bracket.

REMOVE TRANSFER OIL PUMP PLATE

1. 

   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. 

   Remove the transfer oil seal ring from the input shaft.

4. 

   Remove the oil pump drive rotor from the input shaft.

REMOVE TRANSFER CASE STRAIGHT PIN

1. 

   Remove the 2 straight pins.

   Note:

   Do not drop the straight pins.

REMOVE TRANSFER CASE PLUG

1. 

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

REMOVE TRANSFER OIL PUMP PLATE OIL SEAL

1. 

   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.

   Tip:

   Tape the screwdriver tip before use.

REMOVE FRONT OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY

1. 

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

   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. 

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

   09330-00021

3. 

   Using SST, remove the companion flange.

   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.

REMOVE REAR OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY

1. 

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

   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. 

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

   09330-00021

3. 

   Using SST, remove the companion flange.

   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.

REMOVE NO. 1 TRANSFER CASE PLUG

1. 

   Remove the plug, compression spring and pin.

REMOVE TRANSFER CASE PLUG

1. 

   Using a 6 mm hexagon wrench, remove the plug.

REMOVE REAR TRANSFER CASE ASSEMBLY

1. 

   Remove the 14 bolts.

2. Remove the rear transfer case.

   Tip:

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

REMOVE NO. 2 TRANSFER GEAR SHIFT FORK

1. 

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

2. 

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

REMOVE TRANSFER SHIFT ACTUATOR ASSEMBLY

1. 

   Remove the No. 1 gear shift fork bolt.

2. 

   Remove the 3 bolts.

3. 

   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. 

   Remove the O-ring from the shift actuator.

REMOVE REAR TRANSFER OUTPUT SHAFT ASSEMBLY

1. 

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

2. 

   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. 

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

REMOVE SIDE GEAR SHAFT HOLDER BEARING

1. 

   Using a screwdriver, remove the snap ring.

2. 

   Using SST, remove the bearing.

   09308-00010

REMOVE TRANSFER OIL SEPARATOR SUB-ASSEMBLY

1. 

   Remove the 3 bolts and oil separator.

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

REMOVE TRANSFER INPUT SHAFT ASSEMBLY

1. 

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

2. 

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

REMOVE TRANSFER LOW PLANETARY RING GEAR

1. 

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

2. 

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

REMOVE TRANSFER DRIVEN SPROCKET BEARING

1. 

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

REMOVE NO. 1 TRANSFER INPUT SHAFT SEAL RING

1. 

   Remove the seal ring from the input shaft.

REMOVE TRANSFER INPUT SHAFT BEARING

1. 

   Using a snap ring expander, remove the snap ring.

2. 

   Using SST and a press, press out the bearing.

   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.

   Tip:

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

REMOVE TRANSFER INPUT SHAFT BIMETAL FORMED BUSH

1. 

   Using SST, remove the bush.

   09387-00041

   09387-01021

   09387-01030

   09387-01040

REMOVE TRANSFER INPUT SHAFT PLUG

1. 

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

   09950-70010	09951-07150
   09950-60010	09951-00300

REMOVE TRANSFER OUTPUT SHAFT WASHER

1. 

   Remove the 2 output shaft washers from the output shaft.

REMOVE NO. 1 TRANSFER OUTPUT SHAFT SPACER

1. 

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

2. 

   Remove the output shaft spacer from the output shaft.

3. 

   Remove the seal ring from the output shaft spacer.

4. 

   Remove the straight pin from the output shaft.

REMOVE CENTER DIFFERENTIAL CASE

1. 

   Remove the center differential case from the output shaft.

2. 

   for Manual Transmission:

   Using a snap ring expander, remove the snap ring.

3. 

   for Manual Transmission:

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

4. 

   Using SST, remove the needle roller bearing.

   09308-00010

5. 

   Using SST, remove the needle roller bearing.

   09387-00041

   09387-01021

   09387-01030

   09387-01040

REMOVE TRANSFER OUTPUT SHAFT SPACER

1. 

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

2. 

   Remove the output shaft spacer from the output shaft.

3. 

   Remove the straight pin from the output shaft.

REMOVE TRANSFER DRIVE SPROCKET SUB-ASSEMBLY

1. 

   Remove the drive sprocket from the output shaft.

REMOVE TRANSFER DRIVE SPROCKET BEARING

1. 

   Remove the bearing from the output shaft.

REMOVE REAR TRANSFER OUTPUT SHAFT

1. 

   Using SST and a press, press out the bearing.

   09527-10011

   Note:

   Be careful not to drop or damage the output shaft.

2. 

   Remove the needle roller bearing from the output shaft.