TRANSFER ASSEMBLY DISASSEMBLY


  1. REMOVE PROPELLER SHAFT HEAT INSULATOR BRACKET SUB-ASSEMBLY


    1. A01ENR6

      Remove the bolt and bracket.

  2. REMOVE TRANSFER OIL PUMP PLATE


    1. A01ENOG

      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. A01EOB3

      Remove the transfer oil seal ring from the input shaft.

    4. A01EP33E01

      Remove the oil pump drive rotor from the input shaft.

  3. REMOVE TRANSFER CASE STRAIGHT PIN


    1. A01EQSRE01

      Remove the 2 straight pins.

      Note

      Do not drop the straight pins.

  4. REMOVE TRANSFER CASE PLUG


    1. A01ES3Y

      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. A01ES75

      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. A01EMWDE01

      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. A01ERUYE01

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

      SST
      09330-00021
    3. A01ENRPE01

      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 CASE FRONT OIL SEAL


    1. A01ENAIE01

      Using SST, tap out the oil seal.

      SST
      09308-00010

      Note

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

  8. REMOVE REAR OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY


    1. A01ESM6E01

      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. A01EMVWE01

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

      SST
      09330-00021
    3. A01EQ96E01

      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.

  9. REMOVE TRANSFER CASE REAR OIL SEAL


    1. A01EQSUE01

      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.

  10. REMOVE NO. 1 TRANSFER CASE PLUG


    1. A01EP8O

      Remove the plug, compression spring and pin.

  11. REMOVE TRANSFER CASE PLUG


    1. A01EP2C

      Using a 6 mm hexagon wrench, remove the plug.

  12. REMOVE REAR TRANSFER CASE ASSEMBLY


    1. A01EP44

      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.

  13. REMOVE FRONT TRANSFER OUTPUT SHAFT NEEDLE ROLLER BEARING

    A01EN0YE01

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

  14. REMOVE NO. 2 TRANSFER GEAR SHIFT FORK


    1. A01EP4J

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

    2. A01EPDS

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

  15. REMOVE TRANSFER SHIFT ACTUATOR ASSEMBLY


    1. A01ER9P

      Remove the No. 1 gear shift fork bolt.

    2. A01ENQQ

      Remove the 3 bolts.

    3. A01ENOWE01

      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. A01ES6RE02

      Remove the O-ring from the shift actuator.

  16. REMOVE REAR TRANSFER OUTPUT SHAFT ASSEMBLY


    1. A01EQBX

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

    2. A01EQ3S

      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. A01ERIJ

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

  17. REMOVE FRONT DRIVE CLUTCH SLEEVE

    A01EO0A

    1. Remove the clutch sleeve from the output shaft.

  18. REMOVE SIDE GEAR SHAFT HOLDER BEARING


    1. A01ENDQ

      Using a screwdriver, remove the snap ring.

    2. A01EOP3E01

      Using SST, remove the bearing.

      SST
      09308-00010

  19. REMOVE TRANSFER OIL SEPARATOR SUB-ASSEMBLY


    1. A01EQ0O

      Remove the 3 bolts and oil separator.

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

  20. REMOVE TRANSFER CASE MAGNET

    A01EOJ9

    1. Remove the magnet from the oil separator.

  21. REMOVE TRANSFER INPUT SHAFT ASSEMBLY


    1. A01EPBM

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

    2. A01ENGM

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

  22. REMOVE TRANSFER LOW PLANETARY RING GEAR


    1. A01ESIQ

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

    2. A01EOB5

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

  23. REMOVE TRANSFER DRIVEN SPROCKET BEARING


    1. A01ENSK

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

  24. REMOVE NO. 1 TRANSFER INPUT SHAFT SEAL RING


    1. A01EPMBE01

      Remove the seal ring from the input shaft.

  25. REMOVE TRANSFER INPUT SHAFT BEARING


    1. A01ENTU

      Using a snap ring expander, remove the snap ring.

    2. A01EOM5E01

      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.

  26. REMOVE TRANSFER INPUT SHAFT BIMETAL FORMED BUSH


    1. A01ERAAE01

      Using SST, remove the bush.

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

  27. REMOVE TRANSFER INPUT SHAFT PLUG


    1. A01ER4ZE01

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

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

  28. REMOVE TRANSFER OUTPUT SHAFT WASHER


    1. A01ESF8

      Remove the 2 output shaft washers from the output shaft.

  29. REMOVE NO. 1 TRANSFER OUTPUT SHAFT SPACER


    1. A01ESO2

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

    2. A01ENRM

      Remove the output shaft spacer from the output shaft.

    3. A01ENZ3

      Remove the seal ring from the output shaft spacer.

    4. A01ESLXE01

      Remove the straight pin from the output shaft.

  30. REMOVE CENTER DIFFERENTIAL CASE


    1. A01ERFN

      Remove the center differential case from the output shaft.

    2. A01ENQ9E01

      Using SST, remove the needle roller bearing.

      SST
      09308-00010
    3. A01EPFCE01

      Using SST, remove the needle roller bearing.

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

  31. REMOVE TRANSFER OUTPUT SHAFT SPACER


    1. A01EMZ1

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

    2. A01EOMK

      Remove the output shaft spacer from the output shaft.

    3. A01ER48E01

      Remove the straight pin from the output shaft.

  32. REMOVE TRANSFER DRIVE SPROCKET SUB-ASSEMBLY


    1. A01EPD5

      Remove the drive sprocket from the output shaft.

  33. REMOVE TRANSFER DRIVE SPROCKET BEARING


    1. A01ENH6

      Remove the bearing from the output shaft.

  34. REMOVE REAR TRANSFER OUTPUT SHAFT


    1. A01EO95E01

      Using SST and a press, press out the bearing.

      SST
      09527-10011

      Note

      Be careful not to drop or damage the output shaft.

    2. A01EQT3

      Remove the needle roller bearing from the output shaft.