Disassembly

JF3A TRANSFER / 4WD / AWD: TRANSFER ASSEMBLY: DISASSEMBLY

1. REMOVE HEAT INSULATOR BRACKET

(a) Remove the heat insulator bracket.

2. REMOVE TRANSFER CASE PLUG

(a) Using a 10 mm hexagon wrench, remove the case plug, compression spring, ball and relief valve seat.

3. REMOVE TRANSFER OIL PUMP PLATE

(a) Remove the 4 bolts and oil pump plate.

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

(b) Remove the oil seal ring from the input shaft.

(d) Remove the O-ring from the transfer oil pump plate.

4. REMOVE TRANSFER CASE STRAIGHT PIN

(a) Remove the 2 straight pins.

NOTICE:
Do not drop the straight pins.

5. REMOVE TRANSFER OIL PUMP PLATE OIL SEAL

(a) Using a screwdriver and hammer, tap out the oil seal from the oil pump plate.

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

6. REMOVE FRONT OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY

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

SST : 09930-00010

(b) Using SST to hold the companion flange.

SST : 09330-00021

(e) Remove the front output shaft companion flange sub-assembly.

7. REMOVE TRANSFER CASE FRONT OIL SEAL

(a) Using SST, remove the oil seal from the front case.

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

8. REMOVE REAR OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY

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

SST : 09930-00010

(b) Using SST to hold the companion flange.

SST : 09330-00021

(e) Remove the rear output shaft companion flange sub-assembly.

9. REMOVE TRANSFER CASE REAR OIL SEAL

(a) Using a screwdriver and hammer, tap out the oil seal from the rear case.

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

Remove the 2 output washers.

10. REMOVE NO. 1 TRANSFER CASE PLUG

(a) Remove the No. 1 transfer case plug, compression spring and pin.

11. REMOVE TRANSFER CASE PLUG

(a) Using a 6 mm hexagon wrench, remove the case plug.

12. 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.

13. REMOVE TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING

(a) Remove the transfer output shaft front needle roller bearing from the output shaft.

(b) Remove the output shaft spacer from the output shaft.

14. REMOVE NO. 1 SYNCHRONIZER RING

(a) Remove the No. 1 synchronizer ring from center differential case.

15. REMOVE TRANSFER SHIFT ACTUATOR ASSEMBLY

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

(b) Remove the 2 bolts.

(c) Remove the 3 bolts. Then remove the shift actuator, No.1 gear shift fork and No.2 gear shift fork from the rear case.

(d) Remove the o-ring from the transfer shift actuator assembly.

(e) Remove the washer from the rear case.

16. REMOVE TRANSFER HIGH & LOW CLUTCH SLEEVE

(a) Remove the transfer high and low clutch sleeve from the output shaft.

17. 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.

(d) Using a snap ring expander, remove the snap ring from the rear transfer case.

18. REMOVE SIDE GEAR SHAFT HOLDER BEARING

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

(b) Using SST, remove the bearing.

SST : 09308-00010

19. REMOVE TRANSFER OIL SEPARATOR SUB-ASSEMBLY

(a) Remove the 3 bolts and oil separator.

(b) Remove the O-ring from the oil separator.

20. REMOVE TRANSFER CASE MAGNET

(a) Remove the transfer case magnet.

21. REMOVE INPUT SHAFT ASSEMBLY

(a) Using a 14 mm hexagon wrench, remove the 2 case plugs from the front case.

(b) Remove the snap ring. Then remove the input shaft from the front case.

22. REMOVE TRANSFER LOW PLANETARY RING GEAR

(a) Remove the low planetary ring gear from the front case.

(b) Using a screw driver, remove the snap ring from the front transfer case.

23. REMOVE TRANSFER DRIVEN SPROCKET BEARING

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

(b) Using SST, remove the driven sprocket bearing from the front case.

SST : 09950-60020

09951-00680

SST : 09950-70010

09951-07150

24. REMOVE NO. 1 TRANSFER INPUT SHAFT SEAL RING

(a) Remove the oil seal ring from the input shaft.

25. REMOVE TRANSFER INPUT SHAFT BEARING

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

(b) Using SST and a press, pull out the bearing.

SST : 09555-55010

SST : 09950-00030

SST : 09950-60010

09951-00480

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

26. REMOVE TRANSFER INPUT SHAFT BIMETAL FORMED BUSH

(a) Using SST, remove the bush.

SST : 09387-00041

09387-01021

09387-01030

09387-01040

27. REMOVE TRANSFER INPUT SHAFT PLUG

(a) Using SST and a hammer, tap out the input shaft plug.

SST : 09950-70010

09951-07150

SST : 09950-60010

09951-00350

28. REMOVE NO. 1 TRANSFER OUTPUT SHAFT SPACER

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

(b) Remove the output shaft spacer from the output shaft.

29. REMOVE CENTER DIFFERENTIAL CASE

(a) Remove the straight pin from the output shaft.

(b) Remove the center differential case from the output shaft.

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

(d) Remove the synchromesh shifting key spring and No. 2 synchromesh shifting keys from the center differential case.

30. REMOVE FRONT DRIVE CLUTCH SLEEVE

(a) Remove the front driver clutch sleeve with synchromesh from the output shaft.

(b) Remove the 2 transfer clutch hub bearings from shaft.

(d) Using a screw driver, remove the 2 shifting key snap rings and 3 shifting keys from the driver clutch sleeve.

(e) Remove the transfer clutch hub from the drive clutch sleeve.

31. REMOVE REAR TRANSFER OUTPUT SHAFT

(a) Using SST and a press, press out the bearing.

SST : 09527-10011

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

(b) Remove the transfer drive sprocket sub-assembly from the output shaft.