TRANSFER ASSEMBLY > DISASSEMBLY

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1. REMOVE TRANSFER INDICATOR SWITCH


C097064E01

  1. Remove the switches and gaskets.

    HINT:
    Indicator switch:
    No. 1
    		Indicator switch (neutral position) for A/T
    No. 2
    		Indicator switch (L4 position) for A/T or M/T w/ ABS
    No. 3
    		Indicator switch (4WD) for A/T and M/T



2. REMOVE TRANSFER GEAR SHIFT HEAD (Adapter on type)


G034493E01

  1. Using a pin punch and hammer, remove the 2 slotted pins from the No. 1 and No. 2 gear shift heads.

  1. Remove the No. 1 and No. 2 gear shift heads from the front drive shift fork shaft, and high and low shift fork shaft.



3. REMOVE TRANSFER CONTROL SHIFT LEVER RETAINER SUB-ASSEMBLY (Transfer on type)


C111616

  1. Remove the 4 bolts and retainer.



4. REMOVE TRANSFER CASE COVER SUB-ASSEMBLY (Adapter on type)


C111617

  1. Remove the 4 bolts and case cover.



5. REMOVE BREATHER OIL DEFLECTOR


6. REMOVE TRANSFER BEARING RETAINER SUB-ASSEMBLY


C111638

  1. Remove the 5 bolts and bearing retainer.

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



7. REMOVE TRANSFER COVER OIL SEAL

  1. Using a screwdriver and hammer, tap out the oil seal from the bearing retainer.

    NOTICE:
    Be careful not to damage the oil seal and bearing retainer contact surfaces.



8. REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY (FRONT)

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



    F043429E01

  1. Using SST to hold the companion flange, remove the lock nut.

    SST
    09330-00021  



    F043430E01

  1. Using SST, remove the companion flange.

    SST
    09950-40011   (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04051, 09957-04010, 09958-04011)



9. REMOVE TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL (FRONT)

  1. Using a screwdriver and hammer, tap out the oil seal from the companion flange.

    NOTICE:
    Be careful not to damage the oil seal and companion flange contact surfaces.



10. REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY (REAR)

  1. Remove the companion flange (rear) in the same way as the companion flange (front).

    SST
    09330-00021  
    09950-40011   (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04051, 09957-04010, 09958-04011)



11. REMOVE TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL (REAR)

  1. Using a screwdriver and hammer, tap out the oil seal from the companion flange.

    NOTICE:
    Be careful not to damage the oil seal and companion flange contact surfaces.



12. REMOVE VEHICLE SPEED SENSOR


G022561

  1. Disconnect the sensor connector.

  1. Remove the bolt and sensor with the driven gear.



13. REMOVE SPEEDOMETER DRIVEN GEAR SUB-ASSEMBLY


C113235

  1. Remove the clip and driven gear from the sensor.



    C113234

  1. Remove the O-ring from the driven gear.



14. REMOVE TRANSFER EXTENSION HOUSING SUB-ASSEMBLY

  1. Remove the 5 bolts and extension housing.

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



15. REMOVE TRANSFER EXTENSION HOUSING TYPE T OIL SEAL

  1. Using a screwdriver and hammer, tap out the oil seal.

    NOTICE:
    Be careful not to damage the oil seal and extension housing contact surfaces.



16. REMOVE TRANSFER OUTPUT WASHER


17. REMOVE TRANSFER SPEEDOMETER DRIVE GEAR


18. REMOVE REAR TRANSFER CASE


G039426

  1. Remove the 12 bolts and clamp.

  1. Remove the rear case.

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



19. REMOVE FRONT TRANSFER DRIVE SHIFT FORK SHAFT


C111621E01

  1. Using a hexagon wrench, remove the 2 plugs.

  1. Using a magnetic finger, remove the 2 springs and 2 balls from both holes.

  1. Mount the case rear in a vise.

    NOTICE:
    Place aluminum plates on the vise to prevent damage to the case rear.



    C111622

  1. Using a pin punch and hammer, tap out the 2 slotted pins from the shift shaft stopper and No. 2 gear shift fork.



    C111623

  1. Hold the shift fork shaft in place by hand when removing the pin punch.



    C111624E01

  1. Remove the shift fork shaft, No. 1 gear shift fork, spring and shift shaft stopper.



    C111625

  1. Using a magnetic finger, remove the straight pin.



20. REMOVE TRANSFER HIGH AND LOW SHIFT FORK SHAFT


C111626E01

  1. Remove the shift fork shaft and No. 2 gear shift fork.



21. REMOVE TRANSFER REAR OUTPUT SHAFT, FRONT TRANSFER DRIVE CHAIN AND TRANSFER DRIVEN SPROCKET


C111627

  1. Using a snap ring expander, remove the snap ring.



    C111628E01

  1. Using a plastic-faced hammer, carefully tap the case rear, and remove the output shaft together with the drive chain and driven sprocket.

  1. Remove the output shaft, drive chain and driven sprocket.



22. REMOVE TRANSFER DRIVEN SPROCKET BEARING


F043523

  1. Using a press, press out the bearing.

    NOTICE:
    Be careful not to drop or damage the driven sprocket.



23. REMOVE TRANSFER INPUT GEAR RADIAL BALL BEARING


F043524E01

  1. Using SST, a press and steel bar, press out the bearing.

    SST
    09555-55010  

    NOTICE:
    Be careful not to damage the driven sprocket.



24. REMOVE NO. 1 TRANSFER CASE PLUG (FILLER)

  1. Remove the filler plug and gasket.



25. REMOVE NO. 1 TRANSFER CASE PLUG (DRAIN)

  1. Remove the drain plug and gasket.



26. REMOVE TRANSFER OIL SEPARATOR SUB-ASSEMBLY


F043446

  1. Remove the 3 bolts and oil separator.



27. REMOVE TRANSFER CASE MAGNET


28. REMOVE TRANSFER OIL PUMP BODY SUB-ASSEMBLY


F043447E01

  1. Remove the 3 bolts and oil pump body.



29. REMOVE TRANSFER OIL PUMP BODY O-RING


F043462

  1. Using a screwdriver, remove the O-ring from the oil pump body.

    NOTICE:
    Be careful not to damage the oil pump body.



30. REMOVE TRANSFER OIL PUMP GEAR


F043448

  1. Remove the nut and oil pump gear.



31. REMOVE FRONT TRANSFER DRIVE CLUTCH SYNCHRONIZER RING (M/T)


C111629

  1. Remove the synchronizer ring from the planetary gear.



32. REMOVE TRANSFER LOW PLANETARY GEAR ASSEMBLY WITH TRANSFER INPUT SHAFT


F043449

  1. Using a snap ring expander, remove the snap ring.



    C111630

  1. Remove the low planetary gear with the input shaft.



33. REMOVE TRANSFER CASE PLUG


F043455E01


34. REMOVE COMPRESSION SPRING


35. REMOVE PIN


36. REMOVE TRANSFER LOW PLANETARY RING GEAR


F043456

  1. Using a screwdriver, pry out the snap ring.

    NOTICE:
    Be careful not to damage the case front.

  1. Remove the ring gear from the case front.



37. REMOVE TRANSFER CASE OIL SEAL

  1. Using a screwdriver and hammer, tap out the oil seal (No. 1).

  1. Using a screwdriver and hammer, tap out the oil seal (No. 2).

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



38. REMOVE TRANSFER LOW PLANETARY GEAR SPLINE PIECE


C111631

  1. Using a screwdriver, pry out the snap ring.

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



    C111632

  1. Remove the spline piece.



39. REMOVE TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING


C111633


40. REMOVE TRANSFER INPUT GEAR STOPPER SHAFT SNAP RING


C111634

  1. Using a snap ring expander, remove the snap ring.



41. REMOVE TRANSFER INPUT GEAR STOPPER


G034494E01


42. REMOVE TRANSFER INPUT GEAR STOPPER BALL


43. REMOVE MANUAL TRANSFER PLANETARY CARRIER WASHER


44. REMOVE TRANSFER INPUT SHAFT


C111635E01


45. REMOVE NO. 1 TRANSFER THRUST BEARING RACE


46. REMOVE TRANSFER LOW PLANETARY GEAR BEARING


47. REMOVE NO. 1 TRANSFER INPUT SHAFT SEAL RING


C111636

  1. Remove the 2 seal rings.



48. REMOVE TRANSFER INPUT SHAFT BEARING

  1. Using a snap ring expander, remove the snap ring.



    F043467E01

  1. Using SST and a press, press out the bearing.

    SST
    09554-30011  
    09555-55010  

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



49. REMOVE TRANSFER LOW PLANETARY GEAR BEARING


F043526E01

  1. Using SST, remove the bearing.

    SST
    09612-65014   (09612-01030, 09612-01050)

    NOTICE:
    Hang SST securely between the bearing and low planetary gear.



50. REMOVE TRANSFER CLUTCH HUB (M/T)


C111645

  1. Using a snap ring expander, remove the snap ring.

  1. Remove the high and low clutch sleeve, 3 shifting keys and 2 shifting key springs.

  1. Using a press, press out the clutch hub.

    NOTICE:
    Be careful not to drop or damage the clutch hub.



51. REMOVE TRANSFER CLUTCH HUB (A/T)

  1. Using a snap ring expander, remove the snap ring.

  1. Remove the high and low clutch sleeve.

  1. Using a press, press out the clutch hub.

    NOTICE:
    Be careful not to drop or damage the clutch hub.



52. REMOVE TRANSFER DRIVE SPROCKET SUB-ASSEMBLY (A.D.D. manual shift type)


C111646E01

  1. Using SST and a press, press out the bearing.

    SST
    09555-55010  

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



    C111647E01

  1. Remove the spacer and ball.

  1. Remove the drive sprocket with front drive clutch sleeve.

  1. Remove the needle roller bearing.

  1. Remove the front drive synchronizer ring.

  1. Remove the front drive sleeve, 3 shifting keys and 2 shifting key springs from the drive sprocket.



53. REMOVE TRANSFER DRIVE SPROCKET SUB-ASSEMBLY (Normal shift type)


C111646E01

  1. Using SST and a press, press out the bearing.

    SST
    09555-55010  

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



    C111652E01

  1. Remove the spacer and ball.

  1. Remove the drive sprocket and front drive clutch sleeve.

  1. Remove the needle roller bearing.