Transfer Case Disassembly

1. Remove 4WD switch, then the steel ball.
2. Remove gear shift lever case bolts, then the gear shift lever.

Fig. 2, Gear Select Return Assembly Removal:

3. Remove select return bolt, spring, steel ball and pin, Fig. 2.
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.

Fig. 3, Speedometer Drive Gear Removal:

6. Using removal tool No. J-34757, or equivalent, remove circlip then the speedometer drive gear, Fig. 3.

Fig. 4, Bearing Removal:

7. Remove circlip, then the bearing using suitable puller, Fig. 4.

Fig. 5, Sprocket Bushing And Drive Chain Removal:

8. Remove sprocket bushing and needle bearing from rear output shaft, Fig. 5.
9. Remove sprocket, then the drive chain, Fig. 5.
10. Remove countershaft plate attaching bolt, then the plate.
11. Remove front case bolts, then the case.

Fig. 6, Counter Shaft Removal:

12. Remove input gear needle bearing, countershaft washer and steel ball, Fig. 6.

Fig. 7, Exploded View Of Transfer Case Assembly:

13. Remove countergear, then the countershaft together with needle bearings, spacer, washer and steel ball, Fig. 7.
14. Remove reduction shaft locating spring bolt, spring and ball.

Fig. 8, Reduction Shifter Removal:

15. Remove reduction shift shaft, fork and sleeve, Fig. 8.
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. Using separator tool No. J-22912-01, or equivalent, and a suitable press, remove output rear shaft bearing.
22. Remove center case rear oil seal.
23. Remove output front shaft and bearings.
24. Using separator plate tool No. J-22912-01, or equivalent, and a suitable press, remove rear bearings from shaft.

Fig. 9, Front Shaft Bearing Removal:

25. Remove front side bearings, Fig. 9.

Fig. 10, Center Case Needle Bearing Removal:

26. Remove needle bearing from center case using tool Nos. J-34844 and J26941, or equivalents, Fig. 10.
27. Using removal tool Nos. J-26941 and J-23907, or equivalent, remove rear case oil seal.
28. Using tool Nos. J-34844 and J-26941, or equivalents, remove needle bearing from rear case.
29. Remove input gear bearing circlip from front case.
30. Remove input gear from case, then the input bearing circlip and bearing.

Fig. 11, Front Drive Fork And Spring Removal:

31. Remove circlip, then compress fork and spring on front drive fork shaft and remove shaft, Fig. 11.
32. Remove oil gutter.