Minor Component

Transfer Rear Case Assembly:

MINOR COMPONENT (TRANSFER CASE)

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-22912-01




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, [1][2]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 and Washer
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
Using screw driver to remove the bearing collar.




11. 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.




14. Ball Bearing
Use a bench press and the ball bearing remover to remove the ball bearing.
Bearing Remover : J-22912-01




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




23. Ball Bearing
Use a bench press and the bearing remover to remove the ball bearing.
Bearing Remover : J-22912-01




27. Snap Ring
28. Ball Bearing
29. Snap Ring
30. 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:

MINOR COMPONENT (TRANSMISSION)

Important Operations




3. Detent Ball
Use a magnetic tool 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. Inter lock 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 rod 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 (3).
2. Remove the retainer together with the bearing (4) and the oil seal collar (5)
The universal puller may be used in place of the retaining ring remover.
Retainer Remover : J-37222
Universal Puller : J-8433




6. Reverse Idler Gear Snap Ring
Use a pair of snap ring pliers to remove the snap ring.




7. Bearing Snap Ring
8. Ball Bearing
9. 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 toward you and hold it.
Use the bearing remover to remove the ball bearing and the counter 5th gear together with reverse idler gear assembly.




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




18. 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.
Hub Nut Wrench : J-37219




19. Rev.-5th Synchronizer Assembly
20. Reverse Ring
21. 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.




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




24. Ball Bearing Snap Ring
25. 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.




TOP 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-22912-01




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 replacer 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.




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




18. 1st-2nd Synchronizer Assembly
19. 2nd Block Ring
20. 2nd Gear
1. Use a bench press and the bearing remover to remove the ball bearing 2nd gear together with synchronizer assembly.
Remover : J-22912-01
2. Disassemble the synchronizer assembly.
(1) Springs
(2) Sleeve
(3) Clutch Hub
(4) Inserts




24. Front Ball Bearing
Use a bench press and the bearing remover to remove the ball bearings.
Bearing Remover : J-22912-01