Part 2

SHIFT FORKS AND MAINSHAFT










1. Remove the bolts (3)(Figure 16) that hold the shift motor assembly (2) to the transfer case (1).










2. Remove the shift motor assembly (2)(Figure 17) from the transfer case (1).










3. Remove the sector support with Socket.
4. Loosen detent plug (2)(Figure 18).










5. Remove detent plug (2), spring (3), and plunger (4)(Figure 19). Note that the plug has an O-ring seal. Remove and discard this seal.










6. Using a screw mounted in a slide hammer, remove the front output shaft seal.
7. Remove the front output shaft snap-ring (2)(Figure 20).










8. Remove front output shaft (2) from bearing in front case (1)(Figure 21).










9. Pull mainshaft assembly (2) out of input gear, mode sleeve, and front case (1)(Figure 22).










10. Remove mode fork, mode sleeve (1), and shift rail (2) as assembly. Note which way the sleeve fits in the fork (long side of sleeve goes to front or the points on the sleeve teeth go to the rear of case).










11. Remove range fork (2)(Figure 24) and hub (1) as an assembly. Note fork position for installation reference.










12. Remove the shift sector (1)(Figure 25).

MAINSHAFT










1. Remove the clutch gear (2)(Figure 26) from the output shaft (1).










2. Remove the mode hub (2) retaining ring (3)(Figure 27) from the mainshaft (1).










3. Remove the mode hub (2)(Figure 28) from the mainshaft (1).










4. Remove the drive sprocket drive hub (2)(Figure 29) from the mainshaft (1).

INPUT AND PLANETARY GEAR










1. Remove input gear seal with suitable screw and slide hammer.
2. Remove input gear (1) retaining ring (2)(Figure 30) 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)(Figure 31). Tap gear out of bearing with plastic mallet, if necessary.










4. Remove snap-ring (2)(Figure 32) that retains input gear (1) in the low range gear.










5. Remove retainer (2)(Figure 33).










6. Remove front thrust plate (2)(Figure 34).










7. Remove input gear (1)(Figure 35).










8. Remove bottom tabbed thrust washer (2) from low range planetary (1)(Figure 36).