Transfer Disassembly

TRANSFER DISASSEMBLY





1. REMOVE NO.1 SPEED SENSOR
2. REMOVE TRANSFER INDICATOR SWITCH




3. REMOVE FRONT COMPANION FLANGE
(a) Using a hammer and chisel, loosen the staked part of the nut.
(b) Using SST to hold the flange, remove the nut and washer.
SST 09330-00021
(c) Remove the companion flange.

HINT: If the companion flange is difficult to remove, use SST.




4. REMOVE REAR COMPANION FLANGE
(a) Using a hammer and chisel, loosen the staked part of the nut.
(b) Using SST to hold the flange, remove the nut and washer.
SST 09330-00021
(c) Remove the companion flange.




5. REMOVE EXTENSION HOUSING
Remove the 7 bolts and remove the extension housing.




6. REMOVE SPEEDOMETER DRIVE GEAR, STEEL BALL. OIL PUMP SCREW AND BEARING




7. REMOVE REAR CASE
(a) Remove the 1 0 bolts.
(b) Using a plastic hammer, remove the rear case with the idler gear.

HINT: Hold the front case so the rear does not descend. If it descends, the clutch hub and steel ball may fall out.




8. REMOVE IDLER GEAR FROM REAR CASE
(a) Using a snap ring expander. remove the snap ring.
(b) Using a plastic hammer, tap out the idler gear from the rear case.

HINT: Place the rear case on something soft such as wooden blocks.




9. REMOVE BEARING RETAINER
Remove the 4 bolts and remove the bearing retainer.




10. REMOVE FRONT DRIVE GEAR
(a) Using a snap ring expander, remove the snap ring.
(b) Using a plastic hammer, tap out the front drive gear from the front case.




11. REMOVE OIL PIPES
Using pliers, remove the 2 oil pipes.




12. REMOVE SHIFT NO.1 FORK AND CLUTCH SLEEVE
(a) Shift the fork shafts to the high-low position.
(b) Using a pin punch and a hammer, drive out the slotted spring pin.
(c) Remove the shift No.1 fork together with the clutch sleeve.




13. REMOVE CLUTCH HUB AND TRANSFER DRIVE GEAR
Using SST, remove clutch hub and transfer drive gear.
SST 09950-40010




14. REMOVE NEEDLE ROLLER BEARING, NO.2 SPACER AND STEEL BALL




15. REMOVE TRANSFER CASE COVER
Remove the 4 bolts and remove the transfer case cover and gasket.




16. REMOVE STRAIGHT SCREW PLUGS, SPRINGS AND LOCKING BALLS
(a) Using a hexagon wrench, remove the plug on the right side.
(b) Using a magnetic finger, remove the spring and ball.
(c) Similarly, remove the plug, spring and ball on the left side.




17. REMOVE FRONT DRIVE SHIFT FORK SHAFT
18. REMOVE INTERLOCK PIN
Using a magnetic finger, remove the interlock pin.




19. REMOVE HIGH AND LOW SHIFT FORK SHAFT
(a) Using a pin punch and a hammer, drive out the slotted spring pin.
(b) Remove the shaft.




20. REMOVE FRONT CASE
(a) Remove the 4 bolts.




(b) Using a plastic hammer, remove the front case with the output shaft.




21. REMOVE NO.2 FORK WITH CLUTCH SLEEVE AND NEEDLE ROLLER BEARING FROM INPUT SHAFT




22. REMOVE INPUT GEAR AND COUNTER GEAR FROM REDUCTION GEAR CASE
(a) Using a snap ring expander, remove the 2 snap rings.
(b) Using a plastic hammer, tap out the input gear and counter gear from the reduction gear case.

HINT: Place the reduction gear case on something soft such as wooden blocks.




23. REMOVE OUTPUT SHAFT FROM FRONT CASE
(a) Remove the 4 bearing retainer bolts and remove the bearing retainer.




(b) Using a snap ring expander, remove the snap ring.
(c) Using a plastic hammer, tap out the output shaft from the front case.

HINT: Place the front case on something soft such as wooden blocks.