Part 1

OVERHAUL
1. REMOVE ENGINE UNDER COVER SUB-ASSY NO.1
2. REMOVE ENGINE UNDER COVER ASSY REAR
3. DISCONNECT OXYGEN SENSOR
4. REMOVE EXHAUST PIPE ASSY
5. REMOVE PROPELLER SHAFT ASSY FRONT
6. REMOVE PROPELLER SHAFT ASSY
7. DRAIN AUTOMATIC TRANSMISSION FLUID
8. DRAIN TRANSFER OIL
9. REMOVE FRONT SUSPENSION MEMBER BRACKET
10. REMOVE FRONT SUSPENSION MEMBER BRACKET LH
11. REMOVE TRANSMISSION OIL FILLER TUBE SUB-ASSY
12. DISCONNECT OIL COOLER OUTLET TUBE NO.1
SST 09023-12700
13. REMOVE OIL COOLER INLET TUBE NO.1
SST 09023-12700
14. DISCONNECT TRANSMISSION CONTROL CABLE ASSY
15. REMOVE TRANSMISSION CONTROL CABLE BRACKET NO.1





16. REMOVE TRANSFER CASE LOWER PROTECTOR
a) Remove the 4 bolts and transfer case lower protector.
17. SUPPORT AUTOMATIC TRANSMISSION W/TRANSFER
18. REMOVE FRAME CROSSMEMBER SUB-ASSY NO.3
19. DISCONNECT CONNECTOR
20. DISCONNECT WIRE HARNESS
21. REMOVE STARTER ASSY
22. REMOVE MANIFOLD STAY
23. REMOVE MANIFOLD STAY NO.2
24. SEPARATE FRONT DIFFERENTIAL ASSY
25. REMOVE AUTOMATIC TRANSMISSION W/TRANSFER





26. REMOVE TRANSFER ASSY
a) Remove the 8 bolts and 2 clamps.
b) Remove the transfer from the automatic transmission.
27. REMOVE HOSE





28. REMOVE TRANSFER FRONT BEARING RETAINER SUB-ASSY
a) Remove the 5 bolts and front bearing retainer sub-assy.

HINT: If necessary, tap the front bearing retainer sub-assy with a plastic hammer to remove it.

29. REMOVE TRANSFER COVER TYPE T OIL SEAL
a) Using a screwdriver and hammer, remove the oil seal from the front bearing retainer sub-assy.





30. REMOVE TRANSFER CASE COVER SUB-ASSY
a) Remove the 4 bolts and case cover sub-assy.
31. REMOVE BREATHER OIL DEFLECTOR





32. REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSY
a) Using a chisel and hammer, loosen the staked part of the output shaft companion flange lock nut.
b) Using SST to hold the output shaft companion flange, remove the output shaft companion flange lock nut.
SST 09330-00021





c) Using SST, remove the output shaft companion flange sub-assy.
SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04051, 09957-04010, 09958-04011)
33. REMOVE TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL
a) Using a screwdriver and hammer, remove the oil seal from the output shaft companion flange sub-assy.
34. REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSY
a) Remove the rear output shaft companion flange sub-assy in the same way as the front output shaft companion flange sub-assy.
SST 09330-00021, 09950-40011 (09951-04020, 09952-04010, 09953~04030, 09954-04010, 09955-04051, 09957-04010, 09958-04011)
35. REMOVE TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL
a) Using a screwdriver and hammer, remove the oil seal from the rear output shaft companion flange sub-assy.





36. REMOVE TRANSFER EXTENSION HOUSING SUB-ASSY REAR
a) Remove the 5 bolts and extension housing sub-assy rear.

HINT: If necessary, tap the extension housing sub-assy rear with a plastic hammer to remove it.

37. REMOVE OIL (TRANSFER EXTENSION HOUSING SUB-ASSY REAR) SEAL
a) Using a screwdriver and hammer, remove the oil seal.





38. REMOVE TRANSFER OUTPUT WASHER
39. REMOVE COLLAR





40. REMOVE TRANSFER CASE REAR
a) Remove the 12 bolts and clamp.
b) Remove the transfer case rear.

HINT: If necessary, tap the transfer case rear with a plastic hammer to remove it.





41. REMOVE TRANSFER GEAR SHIFT FORK NO.2 W/TRANSFER HIGH AND LOW CLUTCH SLEEVE
a) Remove the bolt, gear shift fork No.2 and high and low clutch sleeve.





42. REMOVE TRANSFER SHIFT SHAFT STOPPER
a) Remove the bolt and shift shaft stopper.
43. REMOVE TRANSFER FRONT DRIVE SHIFT FORK SHAFT
a) Turn the front drive shift fork shaft, and remove it from the rear case aligning the cut out position and the inter-lock pin position.





44. REMOVE ROLLER SHIFT INTER-LOCK PIN
a) Using a magnetic finger, remove the 2 shift inter-lock pin.
45. REMOVE NO.2 STOPPER TRANSFER SHIFT SHAFT





46. REMOVE REAR OUTPUT SHAFT SUB-ASSY, GEAR SHIFT FORK NO.1, FRONT DRIVE CLUTCH SLEEVE, FRONT DRIVE CHAIN AND DRIVEN SPROCKET
a) Using 2 screwdrivers and a hammer, tap out the snap ring.





b) Using 2 screwdrivers and a hammer, tap out the snap ring.





c) Using a snap ring expander, remove the snap ring.





d) Mount the transfer case rear in a vise.
e) Using a plastic hammer, carefully tap the transfer case rear, and remove the rear output shaft sub-assy together with gear shift fork No.1, front drive clutch sleeve, front drive chain and driven sprocket sub-assy.





f) Remove the rear output shaft sub-assy, gear shift fork No.1, front drive chain and driven sprocket sub-assy.





47. REMOVE NO.2 STOPPER TRANSFER SHIFT SHAFT





48. REMOVE TRANSFER DRIVEN SPROCKET BEARING
a) Using a press, remove the driven sprocket bearing.





49. REMOVE TRANSFER INPUT GEAR RADIAL BALL BEARING
a) Using SST, a press and steel bar, remove the transfer input gear radial ball bearing.
SST 09555-55010





50. REMOVE TRANSFER SHIFT ACTUATOR ASSY
a) Using 2 screwdrivers and a hammer, tap out the snap ring.





b) Remove the 3 bolts and transfer shift actuator assy.
51. REMOVE TRANSFER CASE NO.1 PLUG
a) Remove the transfer case No.1 plug (filler plug) and gasket.
52. REMOVE TRANSFER CASE NO.1 PLUG
a) Remove the transfer case No.1 plug (drain plug) and gasket.





53. REMOVE TRANSFER OIL SEPARATOR SUB-ASSY
a) Remove the 3 bolts and oil separator sub-assy.
54. REMOVE TRANSFER CASE MAGNET





55. REMOVE TRANSFER OIL PUMP BODY SUB-ASSY
a) Remove the 3 bolts and oil pump body sub-assy.





56. REMOVE TRANSFER OIL PUMP BODY D-RING
a) Using a screwdriver, remove the oil pump body O-ring.





57. REMOVE TRANSFER OIL PUMP GEAR





58. REMOVE LOW PLANETARY GEAR ASSY W/INPUT SHAFT SUB-ASSY
a) Using a snap ring expander, remove the snap ring.





b) Remove the low planetary gear assy and input shaft sub-assy.





59. REMOVE TRANSFER OUTPUT SHAFT SPACER
60. REMOVE TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING
61. REMOVE TRANSFER CASE OIL SEAL
a) Using a screwdriver and hammer, remove the transfer case oil seal.





62. REMOVE TRANSFER INPUT GEAR STOPPER SHAFT SNAP RING
a) Using a snap ring expander, remove the input gear stopper shaft snap ring.





63. REMOVE TRANSFER INPUT GEAR STOPPER
64. REMOVE TRANSFER INPUT GEAR STOPPER BALL
65. REMOVE MANUAL TRANSFER PLANETARY CAR WASHER





66. REMOVE SHAFT, TRANSFER INPUT
67. REMOVE TRANSFER THRUST BEARING RACE NO.1
68. REMOVE TRANSFER LOW PLANETARY GEAR BEARING





69. REMOVE TRANSFER INPUT SHAFT SEAL RING NO.1





70. INSPECT SHAFT, TRANSFER INPUT
a) Using a micrometer, measure the outer diameter of the input shaft journal surface.
Minimum diameter: 47.59 mm (1.8736 inch)
If the outer diameter is less than the minimum, replace the input shaft.





b) Using a dial indicator, measure the inside diameter of the input shaft bushing.
Maximum diameter: 48.14 mm (1.8953 inch)
If the inside diameter exceeds the maximum, replace the input shaft.