Steps 1 - 51

52. Remove the clutch hub retaining ring.





Important: Do not remove the oil restrictor plate on the 2nd design clutch hub. The oil restrictor plate is only serviced with the clutch hub.

53. If 1st design, remove the clutch hub oil restrictor plate.

54. Remove the clutch housing and hub assembly from the rear output shaft.





55. If 1st design, turn the clutch assembly over on a work bench.
56. If 1st design, remove the clutch housing.
57. If 1st design, remove the clutch hub.
58. If 1st design, remove the clutch backing plate.





59. If 2nd design, remove the clutch housing

60. If 2nd design, remove the clutch hub.





Important: Do not wash the clutch friction or inner pressure plates in cleaning solvent.

61. Separate the clutch plates for inspection.
62. Remove and discard the shim or shims.





63. Remove the oil restrictor from the rear output shaft, if replacing the shaft.





64. Inspect the bearing in the clutch housing for being faulty.
65. If the bearing is faulty, use a brass drift and a hammer to remove the bearing.





66. Remove both of the clutch lever pivot pins.





67. Remove the shift detent spring bolt.
68. Remove the following components:
^ The shift detent plunger plug O-ring seal
^ The shift detent spring
^ The shift detent plunger





69. Remove the clutch lever from the control actuator lever.





70. Remove the shift fork shaft.





71. Remove the range shift fork and the range shift sleeve as an assembly.
It may be necessary to pry the roller on the shift fork from the control actuator lever.





72. Remove the range shift sleeve from the range shift fork.





73. Remove the outer retaining ring for the input gear bearing.





Important: The transfer case may use either a 4 pinion or 6 pinion planetary carrier assembly with the 27 tooth input gear version of the transfer case, transmission RPO M30. If the 6 pinion planetary carrier assembly used with the 27 tooth input gear requires replacement, the service part will be a 4 pinion planetary carrier assembly. The 4 pinion and 6 pinion planetary carriers are interchangeable. The 32 tooth input gear transfer case version used with transmission RPO MT1 and RPO MN8 will still use the 6 pinion planetary carrier assembly.

74. Remove the high/low planetary carrier.




75. Remove the planetary gear shaft retaining ring.





76. Remove the input shaft thrust bearing washer.





77. Remove the input shaft thrust bearing.





78. Remove the input gear from the planetary carrier.





79. Remove the thrust washer.





80. Inspect the pilot bearing in the input gear for being faulty.
81. Remove the pilot bearing from the input gear using a brass drift and a hammer.





82. Remove the inner retaining ring for the front output shaft bearing.





83. Using a softface hammer, remove the front output shaft, with the bearing, from the front case halt.





84. Using a suitable punch, remove the front output shaft seal from the front case half.





85. Remove the outer retaining ring for the front output shaft bearing.





86. Inspect the front output shaft bearing for being faulty.
87. Remove the bearing from the front output shaft. Do not use the bearing again after removal.





88. If damaged, remove the speed sensor reluctor wheel from the front output shaft, using a hydraulic press. Do not use the speed sensor reluctor wheel again after removal.





89. If the cup plug in the front output shaft is leaking, remove the plug using a brass drift.





90. Remove the input bearing retaining ring.





91. Remove the input bearing.





92. Inspect the front output shaft rear bearing for being faulty.
93. If the bearing is faulty, remove the bearing using the J 23907 (2) and the J 26941 (1).





94. Remove the retaining ring for the control actuator lever shaft.





95. Remove the control actuator lever shaft.
96. Inspect the control actuator lever bearing and seal for being faulty.
97. If the bearing is leaking or faulty, remove the bearing from the case.





98. Remove the drain and fill plugs.