Disassembly

Disassembly

Remove the fill and drain plugs.

Remove the front yoke.

Discard the yoke seal washer and yoke nut.

Turn the transfer case on its end and position the front case half on wooden blocks.

Shift the transfer case to the 4-Low position.

Remove the extension housing attaching bolts. Using a hammer, tap the shoulder on the extension housing to break the sealer loose.





Remove the rear bearing snap ring (1) from the mainshaft and discard.

Remove the rear retainer attaching bolts.





Using a hammer, tap the shoulder on the retainer to break the sealer loose.





Remove the rear retainer (2) and the pump housing (3) from the transfer case.

Remove the pump seal from the pump housing and discard.

Remove the speedometer drive gear from the mainshaft.

Remove the pump gear from the mainshaft.





Remove the bolts attaching the rear transfer case half to the front case half and remove the rear case half. To separate the transfer case, insert screwdrivers into the slots casted in the transfer case ends and pry upward. DO NOT attempt to wedge the transfer case halves apart at any point on the mating surfaces.





Remove the front output shaft (4) and drive chain (5) as an assembly. It may be necessary to raise the mainshaft slightly for the output shaft to clear the transfer case.





Pull up on the mode fork rail (6) until the rail clears the range fork.

Rotate the mode fork (7) and rail and remove it from the transfer case.





Pull up on the mainshaft (8) until it separates from the planetary assembly (9). Remove the mainshaft from the transfer case.





Remove the planetary assembly (9) with the range fork (10) from the transfer case.





Remove the planetary thrust washer, the thrust bearing (11) on the input gear (12) and the front thrust washer (13) from the transfer case.

Remove the shift sector detent spring and the retaining bolt.





Remove the shift sector (14), shaft and spacer (15) from the transfer case.





Remove the locking plate retaining bolts and the locking plate (16) from the transfer case.





Remove the input gear pilot bearing using Tool J-29369-1 with a slide hammer J-261 9-01.

Remove the front output shaft seal, input shaft seal and the rear extension seal using a screwdriver or a brass drift.





Using Tool J-33841 with Tool J-8092, press the two caged roller bearings (for the input shaft gear) from the transfer case.





Using Tool J-29369-1 with a slide hammer J-261 9-01, remove the front output shaft rear bearing.

Using a hammer and drift, remove the rear mainshaft bearing from the rear retainer.





Using a screwdriver, remove the snap ring (17) that retains the front output shaft bearing. Using a hammer and drift, remove the bearing from the transfer case.





Remove the bushing from the extension housing using Tool J-33839 with Tool J-8092. Press the bushing from the extension housing.





Using Tools J-33826 and J-8092, press the two caged roller bearings from the drive sprocket.

Remove the synchronizer keys and retaining rings from the synchronizer hub.

Clean and inspect all components. Replace any components that are excessively worn, distorted or damaged.





Mainshalt Disassembly

Remove the snap ring retaining the synchronizer hub (18) from the mainshaft (8).

Using a brass hammer, tap the synchronizer hub from the mainshaft.

Remove the drive sprocket (19), thrust washer and blocker ring.

Planetary Gear Disassembly





Remove the snap ring (20) retaining the planetary gear (9) in the annulus gear (21).





Remove the outer thrust ring (22) and discard.

Remove the planetary assembly (9) from the annulus gear.

Remove the inner thrust ring (23) from the planetary gear assembly (9) and discard.

Clean and inspect all components. Replace any components that are excessively worn, distorted or damaged.