Disassemble

TOOLS REQUIRED
^ J-37221 Flange Holder
^ J-37217 Bearing Remover
^ J-37487 Puller
^ J-37219 Lock Nut Wrench
^ Or Equivalent





PREPARATION:
^ Clean the exterior of the unit with solvent.
^ Remove the drain plug from the transmission case and transfer case and drain the lubricant.





1. Clutch release bearing. Remove the clutch release bearing from the transmission case.
2. Shift fork:
a. Remove the snap pin





b. Remove the shift fork pin and shift fork from the fulcrum bridge.
3. Fulcrum bridge:
a. Remove the fulcrum bridge bolts.





b. Remove the fulcrum bridge from the transmission case.
4. Front cover (with oil seal). Remove the front cover and gasket from the transmission case.
5. Snap ring; counter front bearing.





6. Snap ring; top gear bearing. Use a pair of snap ring pliers to remove the snap ring.
7. Speedometer sensor and speedometer driven gear:
a. Remove the speedometer sensor.
b. Remove the plate.
c. Remove the driven gear bush and driven gear.

NOTE: Apply a reference mark to the driven gear bush before removal.

8. Front companion flange.
9. Rear companion flange:





a. Use the flange holder to remove the end nut.
- Flange holder: J-37221
b. Remove the front and rear companion flange.
10. Gear control box assembly.
11. Transfer rear case assembly. Remove the transfer rear case assembly from the transfer case.
12. Detent ball, spring and plug.





13. Spring pin and bridge. Use a spring pin remover to remove the spring pin from the bridge.
14. Spring pin.
15. Spring.





16. 2WD-4WD shift rod. Engage the 2WD-4WD sleeve with front output gear. Remove the spring pin from the block. Remove the shift rod.
17. Shift arm.
18. Shift block.
19. 4WD indicator switch.
20. Interlock pin.





21. Spring. Use a magnetic tool to remove the interlock pin from the transfer case.
22. Select rod assembly.
23. Spring pin.





24. High-low shift rod. Use a spring pin remover to remove the shift arm spring pins from the shift arm and shift block. Remove the high-low shift rod.
25. Shift arm.
26. Shift block.
27. Bearing snap ring. Use a pair of snap ring pliers to remove the snap ring.





28. Ball bearing. Use a bearing remover to remove the ball bearing.
- Bearing remover; J-37217
- Puller: J-37487.
29. Lock nut:
a. Install the front companion flange temporarily.





b. Use the flange holder and lock nut wrench to remove the lock nut.
- Companion flange holder: J-37221
- Lock nut wrench: J-37219.
c. Remove the front companion flange.
30. High-low clutch hub and sleeve





31. Transfer input gear. Use the universal puller to remove the High-low synchronizer assembly, High-low block ring, and transfer input gear.
32. Needle bearing.





33. Bearing collar.
34. Ball.
35. Plate.
36. Bearing snap ring.
37. Front output gear assembly:
a. Use a pair of snap ring pliers to expand the bearing snap ring.





b. Use a plastic hammer to tap the front output gear assembly free.
38. Bearing snap ring.
39. Counter gear assembly. Remove the counter gear assembly from the transfer case.
40. 1-2 and 3-4 indicator switch, pin and ball.
41. Transfer case assembly. Remove the transfer case assembly from the transmission case.
42. Intermediate plate with gear assembly.
43. Transmission case.