TRANSFER ASSEMBLY DISASSEMBLY


  1. REMOVE PROPELLER SHAFT HEAT INSULATOR BRACKET SUB-ASSEMBLY


    1. A015688

      Remove the bolt and bracket.

  2. REMOVE TRANSFER OIL PUMP PLATE


    1. A015870

      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. A015A6G

      Remove the transfer oil seal ring from the input shaft.

    4. A015ALZE01

      Remove the oil pump drive rotor from the input shaft.

  3. REMOVE TRANSFER CASE STRAIGHT PIN


    1. A015DV9E01

      Remove the 2 straight pins.

      Note

      Do not drop the straight pins.

  4. REMOVE TRANSFER CASE PLUG


    1. A0156O8

      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. A015CFI

      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. A015731E01

      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. A015D0JE01

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

      SST
      09330-00021
    3. A015E4XE01

      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. A015DG0E01

      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


    1. A0155D0E01

      Using SST, remove the front transfer case oil seal.

      SST
      09308-10010
      09950-40011   ( 09957-04010 )

      Note


      • Be careful not to damage the front transfer case oil seal and front transfer case contact surface.

      • Apply grease to the tip of SST center bolt before use.

  9. REMOVE REAR OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY


    1. A0156FSE01

      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. A015A1KE01

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

      SST
      09330-00021
    3. A015E22E01

      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


    1. A0158HHE01

      Using SST, tap out the oil seal.

      SST
      09308-00010

      Note

      Be careful not to damage the oil seal and rear transfer case contact surface.

  11. REMOVE NO. 1 TRANSFER CASE PLUG


    1. A0155U0

      Remove the plug, compression spring and pin.

  12. REMOVE TRANSFER CASE PLUG


    1. A0157J2

      Using a 6 mm hexagon wrench, remove the plug.

  13. REMOVE REAR TRANSFER CASE ASSEMBLY


    1. A015CJV

      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

    A0157WVE01

    1. Remove the needle roller bearing and spacer from the output shaft.

  15. REMOVE NO. 2 TRANSFER GEAR SHIFT FORK


    1. A015E1S

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

    2. A0157CL

      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. A015DZ6

      Remove the No. 1 gear shift fork bolt.

    2. A0158U8

      Remove the 3 bolts.

    3. A015BO9E01

      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. A0156SFE02

      Remove the O-ring from the shift actuator.

  17. REMOVE REAR TRANSFER OUTPUT SHAFT ASSEMBLY


    1. A015BYI

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

    2. A015CVD

      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. A015ATC

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

  18. REMOVE FRONT DRIVE CLUTCH SLEEVE

    A015D02

    1. Remove the clutch sleeve from the output shaft.

  19. REMOVE SIDE GEAR SHAFT HOLDER BEARING


    1. A015AQS

      Using a screwdriver, remove the snap ring.

    2. A015BMHE01

      Using SST, remove the bearing.

      SST
      09308-00010

  20. REMOVE TRANSFER OIL SEPARATOR SUB-ASSEMBLY


    1. A0156B6

      Remove the 3 bolts and oil separator.

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

  21. REMOVE TRANSFER CASE MAGNET

    A01570L

    1. Remove the magnet from the oil separator.

  22. REMOVE TRANSFER INPUT SHAFT ASSEMBLY


    1. A01579K

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

    2. A015C2R

      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. A015AQV

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

    2. A015C4U

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

  24. REMOVE TRANSFER DRIVEN SPROCKET BEARING


    1. A0156ZD

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

  25. REMOVE NO. 1 SYNCHRONIZER RING (for Manual Transmission)

    A0158Q1

    1. Remove the synchronizer ring from the input shaft.

  26. REMOVE NO. 1 TRANSFER INPUT SHAFT SEAL RING


    1. A015A2ME01

      Remove the seal ring from the input shaft.

  27. REMOVE TRANSFER INPUT SHAFT BEARING


    1. A015B08

      Using a snap ring expander, remove the snap ring.

    2. A0157J5E01

      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.

  28. REMOVE TRANSFER INPUT SHAFT BIMETAL FORMED BUSH


    1. A015B7HE01

      Using SST, remove the bush.

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

  29. REMOVE TRANSFER INPUT SHAFT PLUG


    1. A015BL6E01

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

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

  30. REMOVE TRANSFER OUTPUT SHAFT WASHER


    1. A0159UJ

      Remove the 2 output shaft washers from the output shaft.

  31. REMOVE NO. 1 TRANSFER OUTPUT SHAFT SPACER


    1. A01574J

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

    2. A015D2J

      Remove the output shaft spacer from the output shaft.

    3. A015CWM

      Remove the seal ring from the output shaft spacer.

    4. A015BR0E01

      Remove the straight pin from the output shaft.

  32. REMOVE CENTER DIFFERENTIAL CASE


    1. A015CNR

      Remove the center differential case from the output shaft.

    2. A015DK5

      for Manual Transmission:

      Using a snap ring expander, remove the snap ring.

    3. A015AQT

      for Manual Transmission:

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

    4. A0155V6E01

      Using SST, remove the needle roller bearing.

      SST
      09308-00010
    5. A0155W1E01

      Using SST, remove the needle roller bearing.

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

  33. REMOVE TRANSFER OUTPUT SHAFT SPACER


    1. A0158MX

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

    2. A015CLX

      Remove the output shaft spacer from the output shaft.

    3. A015CC8E01

      Remove the straight pin from the output shaft.

  34. REMOVE TRANSFER DRIVE SPROCKET SUB-ASSEMBLY


    1. A01573H

      Remove the drive sprocket from the output shaft.

  35. REMOVE TRANSFER DRIVE SPROCKET BEARING


    1. A015BU1

      Remove the bearing from the output shaft.

  36. REMOVE REAR TRANSFER OUTPUT SHAFT


    1. A0155ETE01

      Using SST and a press, press out the bearing.

      SST
      09527-10011

      Note

      Be careful not to drop or damage the output shaft.

    2. A0155KW

      Remove the needle roller bearing from the output shaft.