Unit Disassembly

DISASSEMBLED VIEW


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





2. Use a bearing remover J-37217 and puller J-37487 to remove the ball bearing (2).
3. Install the front companion flange temporarily.





4. Use the Companion flange holder J-8614-11 and lock nut wrench J-37219 to remove the lock nut (3).
5. Remove the front companion flange.
6. Remove snap ring (4). (A/T)





7. Remove the input shaft assembly (5) from the transfer case (42). (A/T)





8. Use the universal puller to remove the high-low clutch hub and sleeve (6), and transfer input gear (7).
9. Remove needle bearing (8).





10. Remove bearing collar (9).
11. Remove ball (10).
12. Remove plate (11).





13. Use a bench press and the ball bearing remover J-22912-01 to remove the ball bearing (12) from the input shaft (13). (A/T)
14. Use a pair of snap ring pliers to remove the bearing snap ring (14).





15. Use a plastic hammer to tap the front output gear assembly (15) free.
16. Remove bearing snap ring (16).





17. Use a bench press and the bearing remover J-22912-01 to remove the following parts.
18. Remove ball bearing (17), bearing collar (18). Remove sub-gear snap ring (19), spacer (20), Belleville spring (21), and sub-gear (anti-lash plate) (22). (M/T) Remove front output gear (23).
19. Remove inside ring (25).
20. Remove outside ring (26).
21. Remove block ring (27).
22. Use a bench press and bearing remover J-22912 to remove 2WD-4WD clutch hub and sleeve assembly (28) and stopper plate (29).

NOTE: Do not reuse the stopper plate.





23. Disassemble the 2WD-4WD clutch hub and sleeve assembly (28).
- Springs (1)
- Inserts (2)
- Clutch Hub (3)
- Sleeve (4)





24. Use a bench press and the ball bearing remover J-22912-01 to remove the ball bearing (30) from front output shaft (31).
25. Remove bearing snap ring (32).
26. Remove the counter gear assembly (33) from the transfer case (42).
27. Use a pair of snap ring pliers to remove the snap ring (34).
28. Use a bench press and the bearing remover J-22912-01 to remove the ball bearing (35).
29. Use a pair of snap ring pliers to remove the snap ring (36).





30. Use a bench press and the bearing remover J-22912-01 to remove the ball bearing (37).
31. Remove spacer (38).
32. Remove Belleville spring (39).
33. Remove sub-gear (anti-lash plate) (40).
34. Remove counter gear (41).
35. Remove transfer case (with oil seal) (42), performing the following steps (M/T)





- Cover the shaft splines with adhesive tape (43).
- Remove the transfer case together with intermediate plate with gear assembly from the transmission case (M/T).
- Remove the transfer case from the intermediate plat with gear assembly (M/T).