Disassemble
New Venture Gear 243:
1. Remove front output yoke.
2. Refer to images, during disassembly of transfer case.
3. Remove indicator lamp switch and 0-ring seal.
4. Remove poppet screw, 0-ring seal, poppet spring and poppet plunger.
5. Remove rear extension housing bolt and rear extension.
6. Remove bearing retainer (snap ring) from mainshaft.
7. Remove pump retainer housing bolts, then pump retainer housing from rear case half.
8. Remove speedometer drive gear or speedometer tone wheel from main- shaft.
9. Remove case bolts from case halves. The two longer case bolts go into doweled case holes. Separate case halves, by prying halves apart at slots cast in case ends. Do not wedge halves apart at any point on mating surface. Ensure oil pump is not damaged when rear case half is removed.
10. Remove oil pump, pickup tube, 0-ring and filter from rear case half.
11. Remove fork shift spring.
12. Remove mainshaft, chain and driven sprocket as a unit from front case half. Mode shift fork and shift rail, will be removed with mainshaft.
13. Remove retainer (snap ring) from mainshaft.
14. Remove synchronizer assembly, then drive sprocket from mainshaft.
New Venture Gear 243:
15. Remove range shift fork and range shift hub and sector and shaft from planetary carrier. It is necessary to rotate sector and shaft to provide clearance when removing fork (51).
16. Remove shift lever nut, washer, shift lever, plastic washer and 0-ring seal from front case half, then remove bearing retainer (snap ring).
17. Remove planetary carrier and input gear from annulus gear using soft faced hammer.
18. Proceed as follows:
a. Remove input bearing from front case half using tool Nos. J-36370 and J-8092, or equivalent.
b. Remove drive sprocket bearings from drive sprocket, using tool Nos. J-29170 and J-8092, or equivalent.
c. Remove needle bearings from input gear, using tool Nos. J-29369-1, J-9276-21 and J-2619, or equivalent.
d. Remove front output bearing retainer snap ring.
e. Remove front output shaft seal from front case half.
f. Remove front output bearing from front case half using tool No. J-3379O, or equivalent.
19. Remove seal from mainshaft extension housing and seal from input bearing retainer.
20. Remove front output rear bearing from rear case half, using tool Nos. J-2619-01 and J-29369-2, or equivalent.
21. Using tool No. J-33790, or equivalent, remove mainshaft bearing from oil pump retainer.
22. Remove magnets from front case half.
23. Mark location of synchronizer hub and sleeve for reference during assembly.
24. Remove main drive synchronizer stop ring from synchronizer sleeve.
25. Remove spring retainer from synchronizer sleeve, then remove synchronizer hub from the synchronizer.
26.Remove oil pump screw from oil pump, then remove inner gear.