Disassembly

JF1A TRANSFER: TRANSFER ASSEMBLY:

DISASSEMBLY

1. REMOVE TRANSFER OIL PUMP PLATE

(a) Remove the 4 bolts and oil pump plate, oil pump drive rotor and oil pump driven rotor.

NOTE: Do not drop the oil pump drive rotor and oil pump driven rotor.

2. REMOVE TRANSFER CASE STRAIGHT PIN

(a) Remove the 2 straight pins.

NOTE: Do not drop the straight pins.

3. REMOVE TRANSFER CASE PLUG

(a) Using a 10 mm hexagon wrench, remove the case plug, compression spring, ball and relief valve seat.
4. REMOVE TRANSFER OIL PUMP PLATE OIL SEAL
(a) Using a screwdriver and hammer, tap out the oil seal from the oil pump plate.

NOTE: Be careful not to damage the oil seal and oil pump plate contact surfaces.

5. REMOVE FRONT OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY

(a) Using a chisel and hammer, loosen the staked part of the lock nut.

(b) Using SST to hold the companion flange, remove the lock nut.
SST: 09330-00021

(c) Using SST, remove the companion flange.
SST: 09950-40011
09951-04020
09952-04010
09953-04030
09954-04010
09955-04051
09957-04010
09958-04011
6. REMOVE TRANSFER CASE FRONT OIL SEAL
(a) Using a screwdriver and hammer, tap out the oil seal from the front case.

NOTE: Be careful not to damage the front case contact surfaces.

7. REMOVE REAR OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY

(a) Using a chisel and hammer, loosen the staked part of the lock nut.

(b) Using SST to hold the companion flange, remove the lock nut.
SST: 09330-00021

(c) Using SST, remove the companion flange.
SST: 09950-40011
09951-04020
09952-04010
09953-04030
09954-04010
09955-04051
09957-04010
09958-04011
8. REMOVE TRANSFER CASE REAR OIL SEAL
(a) Using a screwdriver and hammer, tap out the oil seal from the rear case.

NOTE: Be careful not to damage the rear case contact surfaces.

9. REMOVE NO. 1 TRANSFER CASE PLUG

(a) Remove the case plug, compression spring and pin.
10. REMOVE TRANSFER CASE PLUG

(a) Using a 10 mm hexagon wrench, remove the case plug.
11. REMOVE REAR TRANSFER CASE

(a) Remove the 14 bolts.
(b) Remove the rear case.

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

12. REMOVE NO. 2 TRANSFER GEAR SHIFT FORK

(a) Using 2 screwdrivers and a hammer, tap out the 3 shift fork shaft snap rings.

(b) Remove the bolt. Then remove the No. 2 gear shift fork together with the high and low clutch sleeve from the shift actuator.
13. REMOVE NO. 1 TRANSFER GEAR SHIFT FORK

(a) Remove the bolt. Then remove the No. 1 gear shift fork together with the front drive clutch sleeve from the shift actuator.
14. REMOVE TRANSFER SHIFT ACTUATOR ASSEMBLY

(a) Remove the 3 bolts. Then remove the shift actuator from the rear case.
15. REMOVE REAR OUTPUT SHAFT

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

(b) Using a plastic-faced hammer, carefully tap the case rear, and remove the output shaft together with the drive chain and driven sprocket.
(c) Remove the output shaft and driven sprocket from the drive chain.

NOTE: Do not drop the transfer output washer.

16. REMOVE SIDE GEAR SHAFT HOLDER BEARING

(a) Using a screwdriver, remove the snap ring.

(b) Using a screwdriver, remove the bearing.
17. REMOVE TRANSFER OIL SEPARATOR SUB-ASSEMBLY

(a) Remove the 3 bolts and oil separator.
18. REMOVE TRANSFER CASE MAGNET
19. REMOVE INPUT SHAFT ASSEMBLY

(a) Using a 10 mm hexagon wrench, remove the 2 case plugs from the front case.

(b) Using a snap ring expander, remove the snap ring. Then remove the input shaft from the front case.
20. REMOVE TRANSFER LOW PLANETARY RING GEAR

(a) Using a screwdriver, remove the snap ring. Then remove the low planetary ring gear from the front case.
21. REMOVE TRANSFER DRIVEN SPROCKET BEARING

(a) Using a screwdriver, remove the snap ring. Then remove the driven sprocket bearing from the front case.
22. REMOVE TRANSFER OIL SEAL RING

(a) Remove the oil seal ring from the input shaft.
23. REMOVE NO. 1 TRANSFER INPUT SHAFT SEAL RING

(a) Remove the oil seal ring from the input shaft.
24. REMOVE TRANSFER INPUT SHAFT BEARING

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

(b) Using SST and a press, press out the bearing.
SST: 09555-55010

NOTE: Be careful not to drop or damage the low planetary gear.

25. REMOVE TRANSFER LOW PLANETARY GEAR ASSEMBLY

(a) Using a screwdriver, remove the snap ring.
(b) Remove the transfer low planetary gear assembly and transfer low planetary gear spline piece from the transfer input shaft.
26. REMOVE TRANSFER INPUT SHAFT PLUG

(a) Using SST and a hammer, tap out the input shaft plug.
SST: 09316-60011
09316-00011
27. REMOVE NO. 1 TRANSFER OUTPUT SHAFT SPACER

(a) Using 2 screwdrivers, tap out the snap ring. Then remove the output shaft spacer and front output shaft needle roller bearing from the output shaft.
28. REMOVE TRANSFER SYNCHROMESH SHIFTING KEY SPRING

(a) Using a snap ring expander, remove the snap ring. Then remove the synchromesh shifting key spring and synchromesh shifting key from the output shaft.
29. REMOVE TRANSFER CLUTCH HUB
(a) Using a snap ring expander, remove the snap ring.

(b) Using SST and a press, press out the clutch hub.
SST: 09527-10011

NOTE: Be careful not to drop or damage the output shaft.

30. REMOVE REAR TRANSFER OUTPUT SHAFT RADIAL BALL BEARING

(a) Using SST and a press, press out the bearing.
SST: 09555-55010

NOTE: Be careful not to drop or damage the output shaft.

(b) Remove the drive sprocket and drive sprocket bearing.
(c) Remove the synchronizer ring set.
31. REMOVE TRANSFER DRIVE CLUTCH HUB

(a) Using 2 screwdrivers, tap out the snap ring.

(b) Using SST and a press, press out the drive clutch hub.
SST: 09527-10011