Manual Shift

Fig. 31 Front And Rear Output Shaft Yoke:

Fig. 32 Speedometer Drive Gear:

1. Drain fluid from transfer case, then remove speedometer cover. Install filler plug.
2. Remove both output shaft yoke nuts, washers and rubber seals. Remove rear output yoke from the transfer case, Fig. 31.
3. Remove four wheel drive indicator switch and washer from case. Do not lose this washer.
4. Using tool Nos. T74P-77248-A and T50L-100-A or equivalents, remove front and rear output shaft yoke seals.
5. Using tools mentioned in step 4, remove input shaft seals.
6. Remove four No. 50 Torx head attaching bolts securing rear bearing retainer to cover. Pry rear bearing retainer from cover. Remove all traces of RTV sealer from mating surface.
7. Lift rear output shaft, then using a screwdriver, remove speedometer gear retaining clip, Fig. 32.
8. Slide speedometer gear forward and remove ball using a magnet.
9. Remove speedometer gear.
10. Remove snap ring retaining upper rear ball bearing onto output shaft.
11. Remove twelve No. 50 Torx head bolts securing front case to rear cover. Insert a breaker bar between the pry bosses and separate. Lift front case from rear cover. Remove all traces of RTV sealer from mating surface.
12. Remove front output shaft inner needle bearing from rear cover.
13. Drive out rear output shaft bearing from case.

Fig. 33 2W-4W Sprockets, Lock-up, Chain, Upper And Lower Sprocket Assembly:

Fig. 34 Removing Shift Mode Fork And Lock-up Assembly:

Fig. 35 2W-4W Lock-up Coller Assembly:

Fig. 36 Removing Lower Sprocket Snap Ring:

14. Remove clutch hub snap ring from output shaft. Slide four wheel drive hub off of the output shaft, Fig. 33.
15. Remove spring from shift rail, then lift mode shift fork complete with shifting collar from upper sprocket spline, Fig. 34.
16. Disassemble the 2W-4W lock-up assembly by removing the internal snap ring and pulling lock-up hub and spring from the collar, Fig. 35.
17. Remove lower sprocket to lower output shaft snap ring, Fig. 36. Grasp upper and lower sprocket complete with the chain and lift them out at the same time from the upper and lower output shafts.
18. Remove shift rail by sliding it straight out from shift fork.

Fig. 37 High/Low Shift Fork And Shift Rail:

Fig. 38 Removing Output Shaft Assembly:

Fig. 39 Removing Input Shaft Carrier And Power Take Off Gear:

19. Remove high/low shift fork by first rotating it until the roller is free from the cam, then sliding out of engagement from shifting hub, Fig. 37.
20. Remove chip collecting magnet from case slot.
21. Lift out pump screen, then remove output shaft assembly with pump.
22. Remove high/low shift hub.
23. Remove front output shaft from case, Fig. 38.
24. Turn front case over and remove front oil seal from case.
25. Working through the front opening, expand snap ring from input shaft allowing it to drop out of the bearing.
26. Remove ring gear internal snap ring, then the ring gear.
27. Remove PTO drive gear from input shaft carrier assembly, if equipped, Fig. 39.
28. Remove input shaft bearing to case snap ring.
29. Remove front output shaft bearing to housing snap ring.
30. Remove shift cam by removing the retaining clip and sliding the shift shaft out of the case.
31. Remove shift shaft seal by carefully prying it out of case.
32. Remove shift cam, assist spring and assist spring bushing from case.