Part 2

DISASSEMBLY


SHIFT FORKS AND MAINSHAFT










1. Loosen detent plug (2).
2. Remove the detent plug (2), spring(3), and plunger (4). Note that the plug has an O-ring seal. Remove and discard this seal.










3. Remove the front output shaft snap-ring (2).
4. Remove front output shaft (1) from the front output shaft front bearing.










5. Remove the mainshaft and differential assembly (2) from the input gear and transfer case.










6. Remove the shift rail (1) from the range fork assembly (2) and the front case.










7. Remove range fork (2) and hub as an assembly. Note fork position for installation reference.










8. Remove shift sector (1).










9. Remove the shift sector o-ring (2).

MAINSHAFT










1. Remove intermediate clutch shaft snap-ring (1).










2. Remove the intermediate clutch shaft thrust ring (1).










3. Remove the intermediate clutch shaft (1).










4. Remove the differential snap-ring (1).










5. Remove the differential assembly (1) from the mainshaft (2).










6. Remove the mode hub and mode hub retainer (2) from the differential assembly (1).










7. Remove the mode hub retainer (1) from the mode hub (2).

INPUT AND PLANETARY GEAR










1. Remove the input gear seal with suitable screw and slide hammer.
2. Remove the input gear retaining ring (2) with heavy duty snap-ring pliers.










3. Place front case in horizontal position. Then remove input gear and low range gear as an assembly (2). Tap gear out of bearing with plastic mallet, if necessary.

INPUT AND PLANETARY GEAR










1. Remove the snap-ring (1) that retains input gear in low range gear.










2. Remove the retainer (3).










3. Remove the front tabbed thrust washer (1).










4. Remove the input gear (1).










5. Remove the rear tabbed thrust washer (2) from the low range gear (1).