Part 3
Transfer Case - Mechanical ShiftDisassembly (Steps 41-56)
41. Using the special tools, remove the front output seal.
42. Remove and discard the retaining ring.
1 Install the special tool.
2 Remove and discard the retaining ring.
43. Remove the special tool and the front output shaft.
44. Remove the front output ball bearing retaining ring.
45. Using the special tools and a suitable press, remove the front output ball bearing.
46. Remove the lock plate retaining ring.
47. Lift out the input gear.
^ Inspect the input gear for wear or damage. Install a new gear if necessary.
48. Remove the lock plate.
49. Remove the front input gear thrust washer.
50. Remove the rear input gear thrust washer.
51. Inspect the gear teeth and thrust washers for wear and damage. Install a new planetary gear assembly, if necessary.
52. Remove the poppet assembly.
53. NOTE: If installing a new poppet spring, it must be like in color to the original poppet spring.
Disassemble the poppet screw, the spring and the poppet.
54. Remove the locknut, the washer, the lever, the spacer and the sector assembly.
55. Using the special tool, remove the sector shaft support.
56. Remove and discard the support O-ring seal.
