Disassembly

SEPARATION OF TRANSFER CASE AND EXTENSION ASSEMBLY
1. Separate transfer case (1) and extension assembly (2).
2. Remove transfer driven gear (3) and center differential (4) as a set.
3. Remove thrust washer (5) (52 x 61 x t).





TRANSFER CASE DISASSEMBLY
1. Remove neutral switch (1).

NOTE: Before removing shifter arm, disconnect neutral switch.

2. Draw out shifter arm (2) and remove selector arm (3).
3. Remove plug (4), spring (5) and reverse check ball (6).
4. Remove reverse check sleeve. Disassembly procedure is as follows:





a. Using a standard screwdriver, remove snap ring (A) (Inner-28).

NOTE: Replace snap ring with a new one if deformed or weakened.

b. Remove reverse check plate (B).
c. Remove reverse check spring (C) with cam (D).
d. Remove reverse return spring (E).
e. Remove reverse accent shaft (F)
f. Remove O-ring (G).

NOTE:
- Reverse check sleeve assembly uses an O-ring which should not be scratched.
- Be careful not to break adjustment shim placed between reverse check sleeve assembly and case.





5. Remove back-up light switch (1).
6. Remove oil guide (2).





EXTENSION DISASSEMBLY
1. Remove extension cover (2) and shift bracket (1).
2. Remove snap ring (4) (Outer-30).
3. Remove transfer drive gear (5).

CAUTION: Do not remove ball bearing unless replacing.

4. Remove snap ring (6) (Inner-72).
5. Remove ball bearing (7).

CAUTION: Do not reuse ball bearing.

6. Remove oil seal (8).

CAUTION: Do not reuse oil seal.