TRANSFER ASSEMBLY DISASSEMBLY


  1. REMOVE TRANSFER INDICATOR SWITCH

    A01J3KVE01

    1. Remove the indicator switches and gaskets.

      Tech Tips

      Indicator switch:

      No. 1 Indicator switch (neutral position) for automatic transmission
      No. 2 Indicator switch (L4 position)
      No. 3 Indicator switch (differential lock)

  2. REMOVE TRANSFER GEAR SHIFT HEAD

    A01J3AFE01

    1. Using a pin punch and hammer, tap out the 2 slotted pins from the No. 1 and No. 2 gear shift heads.

    2. Remove the No. 1 and No. 2 gear shift heads from the front drive shift fork shaft and the high and low shift fork shaft.

  3. REMOVE TRANSFER BEARING RETAINER SUB-ASSEMBLY

    A01J37X

    1. Remove the 5 bolts and bearing retainer.

      Tech Tips

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

  4. REMOVE TRANSFER COVER TYPE T OIL SEAL


    1. Using a screwdriver and hammer, tap out the oil seal from the bearing retainer.

      Note

      Be careful not to damage the oil seal and bearing retainer contact surfaces.

  5. REMOVE TRANSFER CONTROL SHIFT LEVER RETAINER SUB-ASSEMBLY (for Transfer on Type)

    A01J301

    1. Remove the 4 bolts and retainer.

  6. REMOVE TRANSFER CASE COVER SUB-ASSEMBLY (for Adapter on Type)

    A01J37S

    1. Remove the 4 bolts and case cover.

  7. REMOVE BREATHER OIL DEFLECTOR

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


    1. Using a chisel and hammer, loosen the staked part of the lock nut.

    2. A01J4O4E01

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

      SST
      09330-00021
    3. A01J32RE01

      Using SST, remove the companion flange.

      SST
      09950-40011   ( 09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04051, 09957-04010, 09958-04011 )

  9. REMOVE TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL (for Front)


    1. Using a screwdriver and hammer, tap out the oil seal from the companion flange.

      Note

      Be careful not to damage the oil seal and companion flange contact surfaces.

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


    1. Remove the companion flange (rear) in the same way as the companion flange (front).

      SST
      09330-00021
      09950-40011   ( 09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04051, 09957-04010, 09958-04011 )

  11. REMOVE TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL (for Rear)


    1. Using a screwdriver and hammer, tap out the oil seal from the companion flange.

      Note

      Be careful not to damage the oil seal and companion flange contact surfaces.

  12. REMOVE SPEEDOMETER DRIVEN GEAR ASSEMBLY WITH VEHICLE SPEED SENSOR


    1. A01J5IL

      Disconnect the connector.

    2. Remove the bolt and speedometer driven gear assembly with vehicle speed sensor from the transfer.

  13. REMOVE SPEEDOMETER DRIVEN GEAR SUB-ASSEMBLY


    1. A01J4CC

      Remove the clip and speedometer driven gear subassembly from the speedometer sensor.

    2. A01J4C4

      Remove the O-ring from the speedometer sensor.

  14. REMOVE TRANSFER EXTENSION HOUSING SUB-ASSEMBLY


    1. Remove the 5 bolts and extension housing.

      Tech Tips

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

  15. REMOVE TRANSFER EXTENSION HOUSING TYPE T OIL SEAL


    1. Using a screwdriver and hammer, tap out the oil seal.

      Note

      Be careful not to damage the oil seal and extension housing contact surfaces.

  16. REMOVE TRANSFER OUTPUT SHAFT WASHER


    1. Remove the 2 washers and drive gear.

  17. REMOVE REAR TRANSFER CASE

    A01J611

    1. Remove the 12 bolts and 2 clamps.

    2. Remove the rear case.

      Tech Tips

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

  18. REMOVE NO. 2 TRANSFER GEAR SHIFT FORK WITH TRANSFER HIGH AND LOW CLUTCH SLEEVE

    A01J7BS

    1. Mount the rear case in a vise.

      Note

      Place aluminum plates on the vise to prevent damage to the rear case.

    2. Using a pin punch and hammer, drive out the slotted spring pin.

    3. Using a hexagon wrench, remove the No. 1 plug.

    4. Using a magnetic finger, remove the spring and ball from the hole.

    5. Remove the No. 2 gear shift fork and high and low shift fork shaft.

    6. Using a magnetic finger, remove the straight pin.

    7. Automatic transmission:

      Remove the high and low clutch sleeve.

    8. Manual transmission:

      Remove the high and low clutch sleeve, 3 shifting keys and 2 No. 1 springs.

  19. REMOVE CENTER DIFFERENTIAL LOCK FORK SUB-ASSEMBLY WITH FRONT DRIVE CLUTCH SLEEVE

    A01J3M6

    1. Mount the rear case in a vise.

      Note

      Place aluminum plates on the vise to prevent damage to the rear case.

    2. Using a pin punch and hammer, drive out the slotted spring pin.

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

    4. Using a hexagon wrench, remove the No. 2 plug.

    5. Using a magnetic finger, remove the spring and ball from the hole.

    6. Remove the center differential lock fork, shift shaft stopper, 2 springs, 3 stoppers, front drive shift shaft and front drive clutch sleeve.

  20. REMOVE REAR TRANSFER OUTPUT SHAFT, FRONT DRIVE CHAIN AND DRIVEN SPROCKET SUB-ASSEMBLY

    A01J461

    1. Mount the rear case in a vise.

      Note

      Place aluminum plates on the vise to prevent damage to the rear case.

    2. Using a snap ring expander, remove the snap ring.

    3. A01J5RH

      Using a plastic-faced hammer, carefully tap the rear case, and remove the output shaft together with the front drive chain and driven sprocket.

    4. Remove the output shaft and driven sprocket from the front drive chain.

  21. REMOVE TRANSFER DRIVEN SPROCKET BEARING

    A01J5Y8

    1. Using a press, press out the bearing.

      Note

      Be careful not to drop or damage the driven sprocket.

  22. REMOVE TRANSFER INPUT GEAR RADIAL BALL BEARING

    A01J5PNE01

    1. Using SST, a press and steel bar, press out the bearing.

      SST
      09555-55010

      Note

      Be careful not to drop or damage the driven sprocket.

  23. REMOVE NO. 1 TRANSFER CASE PLUG (for Filler)


    1. Remove the filler plug and gasket.

  24. REMOVE NO. 1 TRANSFER CASE PLUG (for Drain)


    1. Remove the drain plug and gasket.

  25. REMOVE TRANSFER OIL SEPARATOR SUB-ASSEMBLY

    A01J6HL

    1. Remove the 3 bolts and separator.

  26. REMOVE TRANSFER CASE MAGNET

  27. REMOVE TRANSFER OIL PUMP BODY SUB-ASSEMBLY

    A01J79Q

    1. Remove the 3 bolts and pump body.

  28. REMOVE TRANSFER OIL PUMP BODY O-RING

    A01J51P

    1. Using a screwdriver, remove the O-ring from the pump body.

      Note

      Be careful not to damage the pump body.

  29. REMOVE TRANSFER OIL PUMP GEAR

    A01J6D3

    1. Remove the nut and pump gear.

  30. REMOVE TRANSFER LOW PLANETARY GEAR ASSEMBLY WITH TRANSFER INPUT SHAFT

    A01J4KW

    1. Using a snap ring expander, remove the snap ring.

    2. A01J47W

      Remove the low planetary gear with the input shaft.

  31. REMOVE TRANSFER FRONT DRIVE CLUTCH SYNCHRONIZER RING (for Manual Transmission)

  32. REMOVE OUTPUT SHAFT SPACER

    A01J5VTE01

  33. REMOVE TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING

  34. REMOVE TRANSFER CASE OIL SEAL


    1. Using a screwdriver and hammer, tap out the oil seal (No. 1).

    2. Using a screwdriver and hammer, tap out the oil seal (No. 2).

      Note

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

  35. REMOVE TRANSFER INPUT GEAR STOPPER SHAFT SNAP RING

    A01J5TV

    1. Using a snap ring expander, pry out the snap ring.

  36. REMOVE TRANSFER INPUT GEAR STOPPER

    A01J3GZE01

  37. REMOVE TRANSFER INPUT GEAR STOPPER BALL

  38. REMOVE MANUAL TRANSFER PLANETARY CARRIER WASHER

  39. REMOVE TRANSFER INPUT SHAFT

    A01J4L9E01

  40. REMOVE NO. 1 TRANSFER THRUST BEARING RACE

  41. REMOVE TRANSFER LOW PLANETARY GEAR BEARING

  42. REMOVE NO. 1 TRANSFER INPUT SHAFT SEAL RING

    A01J567

    1. Remove the 2 seal rings.

  43. REMOVE TRANSFER INPUT SHAFT BEARING

    A01J3GKE01

    1. Using a snap ring expander, remove the snap ring.

    2. Using SST and a press, press out the bearing.

      SST
      09554-30011
      09555-55010

      Note

      Be careful not to drop or damage the low planetary gear.

  44. REMOVE TRANSFER LOW PLANETARY GEAR SPLINE PIECE

    A01J49Y

    1. Using a screwdriver, remove the snap ring.

      Note

      Be careful not to damage the spline piece.

    2. Remove the spline piece.

  45. REMOVE TRANSFER LOW PLANETARY GEAR BEARING

    A01J4CUE01

    1. Using SST, remove the bearing.

      SST
      09612-65014   ( 09612-01030, 09612-01050 )

      Note

      Hang SST securely between the bearing and low planetary gear.

  46. REMOVE TRANSFER LOW PLANETARY RING GEAR HOLE SNAP RING

    A01J4UJE01

    1. Using a snap ring expander, remove the snap ring.

  47. REMOVE NO. 2 TRANSFER OUTPUT SHAFT SPACER

  48. REMOVE TRANSFER OUTPUT SHAFT SPACER BALL

  49. REMOVE CENTER DIFFERENTIAL CASE

  50. REMOVE TRANSFER CLUTCH HUB

    A01J66XE01

  51. REMOVE TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING

  52. REMOVE TRANSFER OUTPUT SHAFT PLATE WASHER

  53. REMOVE TRANSFER OUTPUT SHAFT REAR RADIAL BALL BEARING

    A01J3K2E01

    1. Using SST and a press, press out the bearing.

      SST
      09555-55010

  54. REMOVE NO. 1 TRANSFER OUTPUT SHAFT SPACER

    A01J5ZAE02

  55. REMOVE TRANSFER DRIVE SPROCKET SUB-ASSEMBLY

  56. REMOVE TRANSFER DRIVE SPROCKET BEARING

  57. REMOVE TRANSFER OUTPUT SHAFT PLATE WASHER

  58. REMOVE TRANSFER CASE PLUG

    A01J6FDE01

  59. REMOVE COMPRESSION SPRING

  60. REMOVE TRANSFER CASE STRAIGHT PIN

  61. REMOVE TRANSFER LOW PLANETARY RING GEAR

    A01J640

    1. Using a screwdriver, pry out the snap ring.

      Note

      Be careful not to damage the ring gear and front case.

    2. Remove the ring gear from the front case.