Disassembly

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.

Fig. 14:

2. Remove companion flange nut (Fig. 14). 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.

Fig. 15:

4. Remove companion flange rubber seal from front output shaft (Fig. 15).

Fig. 16:

5. Remove nut and washer that retain shift lever to sector shaft. Then remove shift lever from shaft (Fig. 16).

FRONT OUTPUT SHAFT AND DRIVE CHAIN REMOVAL
1. Remove output bearing retaining ring with heavy duty snap ring pliers.
2. Remove output shaft bearing.

Fig. 17:

3. Note position of bolts that attach rear case to front case (Fig. 17). 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.

Fig. 18:

5. Loosen rear case with pry tool to break sealer bead. Insert tool in slot at each end of case (Fig. 18).

Fig. 19:

6. Unseat rear case from alignment dowels (Fig. 19).
7. Remove rear case and oil pump assembly from front case.

Fig. 20:

8. Remove shift rail cup and spring (Fig. 20).

Fig. 21:

9. Remove front sprocket retaining ring (Fig. 21).

Fig. 22:

10. Pull mainshaft, front sprocket and chain outward about 25.4 mm (1 inch) simultaneously (Fig. 22).
11. Remove chain from mainshaft drive sprocket and remove front sprocket and chain as assembly.

SHIFT FORK AND MAINSHAFT REMOVAL

Fig. 23:

1. Remove vacuum/indicator switch (Fig. 23).

Fig. 24:

2. Loosen poppet plunger screw (Fig. 24).

Fig. 25:

3. Remove poppet plunger screw and spring (Fig. 25). Note that screw has O-ring seal. Remove and discard seal this seal.

Fig. 26:

4. Remove poppet plunger with magnet (Fig. 26).

Fig. 27:

5. Remove front output shaft from bearing in case (Fig. 27).

Fig. 28:

6. Pull mainshaft assembly out of input gear, sliding clutch and case (Fig. 28).

Fig. 29:

7. Remove mode fork, sliding clutch and shift rail as assembly (Fig. 29). Note which way clutch fits in fork (long side of clutch goes to front).

Fig. 30:

8. Remove range fork retaining ring (Fig. 30).

Fig. 31:

9. Remove range fork and support sleeve as assembly (Fig. 31).

Fig. 32:

10. Remove shift sector (Fig. 32).

Fig. 33:

11. Remove shift sector shaft nylon retainer and O-ring from shaft bore in front case (Fig. 33).

MAINSHAFT DISASSEMBLY

Fig. 34:

1. Remove retaining ring that secures synchro hub on mainshaft (Fig. 34). Use standard (instead of parallel jaw) snap ring pliers to remove this retaining ring.

Fig. 35:

2. Remove synchro hub (Fig. 35).

Fig. 36:

3. Inspect synchro hub struts and springs. If struts appear worn, remove struts and springs from hub. Note position of springs for installation reference (Fig. 36).

Fig. 37:

4. Remove brass stop ring (Fig. 37). Discard stop ring if worn, cracked, or any teeth are missing.

Fig. 38:

5. Remove drive sprocket (Fig. 38).

INPUT AND PLANETARY GEAR REMOVAL

Fig. 39:

1. Remove input bearing retainer bolts (Fig. 39). A 10 mm socket is required.

Fig. 40:

2. Loosen bearing retainer with pry tool. Insert tool in retainer slot as shown (Fig. 40). Then remove retainer.

Fig. 41:

3. Remove input gear retaining ring with heavy duty parallel jaw snap ring pliers (Fig. 41).

Fig. 42:

4. Tap input gear out of bearing with plastic mallet (Fig. 42).

Fig. 43:

5. Remove input gear and planetary/PTO gear as assembly (Fig. 43).

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.

Fig. 44:

1. Position planetary assembly so PTO gear is on bench (Fig. 44).
2. Remove retaining ring that secures input gear and lock ring in planetary assembly.

Fig. 45:

3. Remove lock ring and front thrust washer from carrier (Fig. 45). Note that lock ring and thrust washer are both tabbed.

Fig. 46:

4. Remove input gear from planetary carrier (Fig 46). Lift gear straight up and out of carrier.

Fig. 47:

5. Remove support sleeve from carrier (Fig. 47).

Fig. 48:

6. Remove rear thrust washer (Fig. 48).