Disassembly
NOTE: Position transfer case in a shallow drain pan. Remove drain plug and drain any remaining lubricant remaining in case.EXTENSION HOUSING REMOVAL
1. Remove extension housing snap ring access cover.
2. Remove bolts holding extension housing to rear case half.
3. Tap extension housing with plastic or rawhide hammer to loosen sealant.
4. Disengage extension housing snap ring from rear output shaft bearing.
5. Separate extension housing from transfer case.
COMPANION FLANGE AND SHIFT LEVER REMOVAL
1. Shift transfer case into neutral.
Removing Companion Flange Nut:
2. Remove companion flange nut. Discard nut after removal. It is not reusable.
3. Remove companion flange from front output shaft. Use a suitable puller if flange can not be removed by hand.
Companion Flange Seal Removal:
4. Remove companion flange rubber seal from front output shaft.
Shift Lever Removal:
5. Remove nut and washer that retain shift lever to sector shaft. Then remove shift lever from shaft.
FRONT OUTPUT SHAFT AND DRIVE CHAIN REMOVAL
1. Remove output bearing retaining ring with heavy duty snap ring pliers.
2. Remove output shaft bearing.
Removing Case Attaching Bolts:
3. Note position of bolts that attach rear case to front case. Some bolts/studs at ends of case require flat washers. Mark position of these bolts with paint or scriber.
4. Remove rear case-to-front case bolts.
Loosening Rear Case (Breaking Sealer Bead):
5. Loosen rear case with pry tool to break sealer bead. Insert tool in slot at each end of case.
Removing Rear Case From Alignment Dowels:
6. Unseat rear case from alignment dowels.
7. Remove rear case and oil pump assembly from front case.
Shift Rail Cup And Spring Removal:
8. Remove shift rail cup and spring.
Removing Front Sprocket Retaining Ring:
9. Remove front sprocket retaining ring.
Removing Drive Schain And Front Sprocket:
10. Pull mainshaft, front sprocket and chain outward about 25.4 mm (1-inch) simultaneously.
11. Remove chain from mainshaft drive sprocket and remove front sprocket and chain as assembly.
SHIFT FORK AND MAINSHAFT REMOVAL
Vacuum/Indicator Switch Removal:
1. Remove vacuum/indicator switch.
Loosening Poppet Plunger Screw:
2. Loosen poppet plunger screw.
Poppet Plunger Screw And Spring Removal:
3. Remove poppet plunger screw and spring. Note that screw has O-ring seal. Remove and discard seal this seal.
Poppet Plunger Removal:
4. Remove poppet plunger with magnet.
Front Output Shaft Removal:
5. Remove front output shaft from bearing in case.
Mainshaft Assembly Removal:
6. Pull mainshaft assembly out of input gear, sliding clutch and case.
Mode Fork, Shift Rail And Sliding Clutch Removal:
7. Remove mode fork, sliding clutch and shift rail as assembly. Note which way clutch fits in fork (long side of clutch goes to front).
Range Fork Retaining Ring Removal:
8. Remove range fork retaining ring.
Range Fork And Support Sleeve Removal:
9. Remove range fork and support sleeve as assembly.
Shift Sector Removal:
10. Remove shift sector.
Removing Sector Shaft O-Ring And Retainer:
11. Remove shift sector shaft nylon retainer and O-ring from shaft bore in front case.
MAINSHAFT DISASSEMBLY
Synchro Hub Retaining Ring Removal:
1. Remove retaining ring that secures synchro hub on mainshaft. Use standard (instead of parallel jaw) snap ring pliers to remove this retaining ring.
Synchro Hub Removal:
2. Remove synchro hub.
Synchro Strut And Spring Removal:
3. Inspect synchro hub struts and springs. If struts appear worn, remove struts and springs from hub. Note position of springs for installation reference.
Synchro Stop Ring Removal:
4. Remove brass stop ring. Discard stop ring if worn, cracked, or any teeth are missing.
Drive Sprocket Removal:
5. Remove drive sprocket.
INPUT AND PLANETARY GEAR REMOVAL
Removing Input Bearing Retainer Bolts:
1. Remove input bearing retainer bolts. A 10 mm socket is required.
Loosening/Removing Input Bearing Retainer:
2. Loosen bearing retainer with pry tool. Insert tool in retainer slot as shown. Then remove retainer.
Removing Input Gear Retaining Ring:
3. Remove input gear retaining ring with heavy duty parallel jaw snap ring pliers.
Removing Inout Gear Retaining Ring:
4. Tap input gear out of bearing with plastic mallet.
Input Gear And Panetary Assembly Removal:
5. Remove input gear and planetary/Power Take-Off (PTO) gear as assembly.
INPUT AND PLANETARY GEAR DISASSEMBLY
The only removable parts in the planetary assembly are the snap rings, needle bearing, thrust washers, lock ring, input gear, and support sleeve. The planetary carrier, PTO gear, planetary pinions, and remaining planetary components are fixed parts and are serviced as an assembly.
Removing Lock Ring/Input Gear Retaining Ring:
1. Position planetary assembly so PTO gear is on bench.
2. Remove retaining ring that secures input gear and lock ring in planetary assembly.
Planetary Lock Ring And Front Thrust Washer Removal:
3. Remove lock ring and front thrust washer from carrier. Note that lock ring and thrust washer are both tabbed.
Removing Input Gear From Planetary Carrier:
4. Remove input gear from planetary carrier. Lift gear straight up and out of carrier.
Support Sleeve Removal:
5. Remove support sleeve from carrier.
Rear Thrust Washer Renmoval:
6. Remove rear thrust washer.