Disassembly

DISASSEMBLY OF EXTERNAL PARTS MAJOR COMPONENTS


Important Operations






2. Transfer Flange - Use the transfer flange holder to remove the transfer flange. Transfer Flange Holder: J-37221






3. Front Cover with Oil Seal
Remove the front cover with oil seal from the transmission case.





4. Counter Gear Snap Ring
5. Bearing Snap Ring
Use a pair of snap ring pliers to remove the snap ring.





DISASSEMBLY OF INTERNAL PARTS MAJOR COMPONENT (TRANSFER CASE)





MAJOR COMPONENT (TRANSMISSION)





TRANSFER REAR CASE ASSEMBLY



Important Operations






2. Bearing Snap Ring. Use a pair of snap ring pliers to remove the snap ring.
4. Bearing Snap Ring
5. Ball Bearing
6. Bearing Snap Ring
1) Use a pair of snap ring pliers to remove the snap rings.





2) Use a bench press and the bearing remover to remove the ball bearing. Bearing Remover: J-22912-O1

9. Bearing Snap Ring
10. Ball Bearing

1) Use a pair of snap ring pliers to remove the snap ring.





2) Use a bench press and the bearing remover to remove the ball bearing.




DETENT, SHIFT FORK ASSEMBLY AND INTERLOCK PIN



Important Operations




2. Bridge - Use a spring pin remover to remove the spring from the bridge.





5. 2WD-4WD Shift Rod
1) Engage the 2nd-4th sleeve with the front output gear.
2) Remove the spring pin from the block.
3) Remove the shift rod.





9. Interlock Pin - Use a magnetic tool to remove the interlock pin from the transfer case.






13. High-Low Shift Rod - Use a spring pin remover to remove the shift arm spring from the shift arm and the shift rod.





TRANSFER CASE ASSEMBLY AND MAINSHAFT GEAR



Important Operations

1. Bearing Snap Ring
2. Mainshaft End Ball Bearing
1) Use a pair of snap ring pliers to remove the snap ring.





2) Use a bearing remover to remove the ball bearing. Remover: J-37217 Puller: J-8433

3. Mainshaft End Lock Nut





1) Engage the 3rd-top synchronizer with the 3rd gear.
2) Engage the low-2nd synchronizer with the low gear.
3) Use the lock nut wrench to remove the lock nut. Lock Nut Wrench: J-37219






4. High-Low Synchronizer Assembly
5. High-Low Block Ring
6. Transfer Input Gear - Use the universal puller to remove the high-low synchronizer assembly the high-low block ring and the transfer input gear.





8. Bearing Collar and Ball - Use a screwdriver to remove the bearing collar.






10. Bearing Snap Ring - Use a pair of snap ring pliers to expand the bearing snap ring. Use a plastic hammer to tap the front output gear assembly free.







13. Ball Bearing - Use a bench press and the ball bearing remover to remove the ball bearing. Bearing Remover: J-22912-O1






15. Sub-Gear Snap Ring - Use a pair of pliers to remove the snap ring.





22. Ball Bearing - Use a bench press and the bearing remover to remove the ball bearing. Bearing Remover: J-22912-O1
26. Snap Ring
27. Ball Bearing
28. Snap Ring





29. Ball Bearing
1) Use a pair of snap ring pliers to remove the snap rings.
2) Use a bench press and the bearing remover to remove the ball bearings.






INTERMEDIATE PLATE AND GEAR ASSEMBLY, DETENT, SHIFT ARM ASSEMBLY, AND INTERLOCK PIN


Important Operations





3. Detent Ball - Use a magnetic hand to remove the detent balls from the intermediate plate. Take care not to lose the detent balls.
8. 3rd-4th Shift Rod
9. 3rd-4th Shift Arm
10. 1st-2nd Shift Arm





1) Hold a round bar against the shift arm end. This will prevent damage to other components.






2) Use a spring pin remover to remove the shift arm spring pin from the shift arm and the shift rod. Discard the used spring pin.
3) Move the 3rd-4th shift rod forward. Take care not to lose the interlock pins.





11. Interlock Pin - Carefully remove the reverse shifter rod forward to avoid losing the interlock pins.

Note: Remove the shifter rods carefully. Interlock pins are located between the shifter rods in the intermediate plate.





REVERSE GEAR AND 5TH GEAR


Important Operations





1. Oil Seal Collar
2. Roller Bearing
3. Retainer
1) Set the retaining ring remover (1) to the retainer (2) and the mainshaft end .
2) Remove the retainer together with the bearing 04 and the oil seal collar. The universal puller may be used in place of the retaining ring remover. Retainer Remover: J-37222 Universal Puller: J-8433





6. Reverse Gear Snap Ring - Use a pair of snap ring pliers to remove the snap rings.
12. Bearing Snap Ring
13. Ball Bearing
14. Counter 5th Gear

1) Use a pair of snap ring pliers to remove the snap rings.
2) Engage the Rev.-5th synchronizer with the 5th gear.
3) Attach the bearing remover to the counter 5th gear.





4) Pull the Rev. shaft forward you and hold it. Use the bearing remover to remove the ball bearing and the counter 5th gear.






18. Needle Bearing - Remove the needle bearing (2 piece type).






19. Clutch Hub Nut
1) Engage the 3rd-4th synchronizer with the 3rd gear.
2) Engage the 1st-2nd synchronizer with the 1st gear.
3) Attach the holding fixture together with the holding base to the mainshaft front bearing and the counter gear front bearing. Holding Fixture: J-37224 Holding Base: J-3289-20





4) Use the hub nut wrench to remove the hub nut. Hug Nut Wrench: J-37219






20. Rev.-5th Synchronizer Assembly
21. Reverse Ring
22. Reverse Gear - Use screw drivers between the reverse gear and bearing plate to remove the Rev.-5th synchronizer assembly together with reverse ring and gear.






24. Bearing Plate and Screw - Use the Torx bit to remove the bearing plate screw from the intermediate plate. Torx Bit Wrench: J-37225 (T45)







25. Ball Bearing Snap Ring
26. Intermediate Plate
1) Insert the snap ring pliers into the mainshaft bearing snap ring hole.
2) Use the snap ring pliers # 1 to force open the mainshaft bearing snap ring # 2. Hold the snap ring open with the pliers.
3) Push the intermediate plate toward the rear of the transmission to remove it. The ball bearing snap ring will come free.




4TH GEAR SHAFT, MAIN GEAR SHAFT, AND COUNTER GEAR


Important Operations






1. Top Gear Shaft Snap Ring
2. Top Gear Shaft
3. Ball Bearing
1) Use a pair of snap ring pliers to remove the snap ring.
2) Use a bench press and the bearing remover to remove the ball bearing. Bearing Remover: J-22912-O1





6. Mainshaft Snap Ring - Use a pair of snap ring pliers to remove the snap ring.





7. 3rd-4th Synchronizer Assembly
1) Use a bench press and the bearing remover to remove the synchronizer assembly as a set.

2) Disassemble the synchronizer assembly.
(1) Springs
(2) Sleeve
(3) Clutch Hub
(4) Inserts
11. Needle Bearing Collar
12. Mainshaft Ball Bearing
13. 1st Gear Thrust Bearing





14. 1st Gear - Use a bench press and the bearing remover to remove the ball bearing.





19. Clutch Hub Snap Ring - Use a pair of snap ring pliers to remove the snap ring.






20. 1st-2nd Synchronizer Assembly
24. 2nd Gear
1) Use a bench press and the bearing remover to remove the ball bearing 2nd gear together with synchronizer assembly. Remover: J-22912-O1
2) Disassemble the synchronizer assembly.
(1) Springs
(2) Sleeve
(3) Clutch Hub
(4) Inserts





28. Front Roller Bearing - Use a bench press and the bearing remover to remove the roller bearings. Bearing Remover: J-22912-O1