Disassembly

Fig. 63 Gear select Return Assembly:

Fig. 64 Speedometer Drive Gear Removal:

Fig. 65 Bearing Removal:

Fig. 66 Sprocket Bushing & Drive Chain Removal:

Fig. 67 Countershaft Removal:

Fig. 68 Exploded View Of Transfer Case Assembly:

Fig. 69 Reduction Shifter Removal:

1. Remove 4WD switch, then the steel ball.
2. Remove gear shift lever case bolts, then the gear shift lever.
3. Remove select return bolt, spring, steel ball and pin, Fig. 63.
4. Remove reduction shift yoke spring pin, then the yoke. If pin falls into case, remove after disassembly.
5. Remove rear case bolts, then separate cases.
6. Remove circlip using removal tool J-34757 or equivalent, then speedometer drive gear, Fig. 64.
7. Remove circlip, then the bearing using suitable puller, Fig. 65.
8. Remove sprocket bushing and needle bearing from rear output shaft, Fig. 66.
9. Remove sprocket, then the drive chain, Fig. 66.
10. Remove countershaft plate attaching bolt, then the plate.
11. Remove front case bolts, then the case.
12. Remove input gear needle bearing, countershaft washer and steel ball, Fig. 67.
13. Remove countergear, then the countershaft together with needle bearings, spacer, washer and steel ball, Fig. 68.
14. Remove reduction shaft locating spring bolt, spring and ball.
15. Remove reduction shift shaft, fork and sleeve, Fig. 69.
16. Place front drive fork shaft at 4WD position.
17. Remove front drive shift locating spring bolt and washer, spring and ball.
18. Remove front drive shift fork, shaft, sleeve and hub.
19. Remove output rear shaft assembly and bearing.
20. Remove circlip from output rear shaft, then the low gear and clutch hub.
21. Remove output rear shaft bearing using separator tool J-22912-01 and a suitable press.
22. Remove center case rear oil seal.
23. Remove output front shaft and bearings.
24. Remove rear bearings from shaft, using separator plate J-22912-01 and a suitable press.

Fig. 70 Front Shaft Bearing Removal:

Fig. 71 Center Case Needle Bearing Removal:

Fig. 72 Front Drive Fork & Spring Removal:

25. Remove front side bearings, Fig. 70.
26. Remove needle bearing from center case using tools J-34844 and J26941, Fig. 71.
27. Remove rear case oil seal using removal tools J-26941 and J-23907.
28. Remove needle bearing from rear case using tools J-34844 and J26941.
29. Remove input gear bearing circlip from front case.
30. Remove input gear from case, then the input bearing circlip and bearing.
31. Remove circlip, then compress fork and spring on front drive fork shaft and remove shaft, Fig. 72.
32. Remove oil gutter.