Disassembly

MAJOR COMPONENTS






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






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






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






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.
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 rod in the intermediate plate.






REVERSE GEAR AND 5TH GEAR






1. Bearing Snap Ring
2. Bearing Snap Ring
3. Ball Bearing
5. Speedometer Drive Gear
1) Use a pair of snap ring pliers to remove the bearing snap ring.
2) Set the bearing remover to the bearing and the mainshaft end to remove the bearing.
Bearing Remover: J-32717 Universal puller: J-8433






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






16. Bearing Snap Ring
17. Ball Bearing
18. Counter 5th Gear
1) Use a pair of snap ring pliers to remove the snap ring.
2) Engage the Rev.- 5th synchronizer with the 5th gear.
3) Attach the bearing remover to the counter gear shaft.
4) Pull the reverse shaft toward you and hold it. Use the bearing remover to remove the ball bearing and the counter 5th gear.






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






23. Mainshaft 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 to the mainshaft and the counter gear. Holding Fixture: J-37224 Holding Base: J-3289-20






4) Use the mainshaft nut wrench to remove the main-shaft nut.
Wrench: J-37219






24. Rev.- 5th Synchronizer Assembly
25. Rev. Block Ring
26. Reverse Gear
Use screw drivers between the reverse gear and bearing plate to remove the Rev.-5th synchronizer assembly together with rev. block ring and gear.






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






29. Needle Bearing
30. Intermediate Plate
1) Insert the snap ring pliers into the mainshaft bearing snap ring hole.Remove the needle bearing (2 piece type)
2) Use the snap ring pliers (1) to force open he main-shaft 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






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 replacer to remove the ball bearing.
Bearing Replacer: 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 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 replacer 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 2nd gear together with synchronizer assembly.
Remover: J-2291 2-01
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 ball bearings. Remover: J-22912-01

TRANSFER CASE Service and Repair