REMOVE PROPELLER SHAFT HEAT INSULATOR BRACKET SUB-ASSEMBLY

REMOVE TRANSFER OIL PUMP PLATE

REMOVE TRANSFER CASE STRAIGHT PIN

REMOVE TRANSFER CASE PLUG

REMOVE TRANSFER OIL PUMP PLATE OIL SEAL

REMOVE FRONT OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY

REMOVE TRANSFER OUTPUT SHAFT DUST DEFLECTOR

REMOVE TRANSFER CASE FRONT OIL SEAL

REMOVE REAR OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY

REMOVE TRANSFER CASE REAR OIL SEAL

REMOVE NO. 1 TRANSFER CASE PLUG

REMOVE TRANSFER CASE PLUG

REMOVE REAR TRANSFER CASE ASSEMBLY

REMOVE FRONT TRANSFER OUTPUT SHAFT NEEDLE ROLLER BEARING

REMOVE NO. 2 TRANSFER GEAR SHIFT FORK

REMOVE TRANSFER SHIFT ACTUATOR ASSEMBLY

REMOVE REAR TRANSFER OUTPUT SHAFT ASSEMBLY

REMOVE FRONT DRIVE CLUTCH SLEEVE

REMOVE SIDE GEAR SHAFT HOLDER BEARING

REMOVE TRANSFER OIL SEPARATOR SUB-ASSEMBLY

REMOVE TRANSFER CASE MAGNET

REMOVE TRANSFER INPUT SHAFT ASSEMBLY

REMOVE TRANSFER LOW PLANETARY RING GEAR

REMOVE TRANSFER DRIVEN SPROCKET BEARING

REMOVE NO. 1 SYNCHRONIZER RING (for Manual Transmission)

REMOVE NO. 1 TRANSFER INPUT SHAFT SEAL RING

REMOVE TRANSFER INPUT SHAFT BEARING

REMOVE TRANSFER INPUT SHAFT BIMETAL FORMED BUSH

REMOVE TRANSFER INPUT SHAFT PLUG

REMOVE TRANSFER OUTPUT SHAFT WASHER

REMOVE NO. 1 TRANSFER OUTPUT SHAFT SPACER

REMOVE CENTER DIFFERENTIAL CASE

REMOVE TRANSFER OUTPUT SHAFT SPACER

REMOVE TRANSFER DRIVE SPROCKET SUB-ASSEMBLY

REMOVE TRANSFER DRIVE SPROCKET BEARING

REMOVE REAR TRANSFER OUTPUT SHAFT

Remove the bolt and bracket.

Remove the 4 bolts, oil pump plate and oil pump driven rotor.

• NOTICE:

• Do not drop the oil pump driven rotor.

Remove the O-ring from the oil pump plate.

Remove the transfer oil seal ring from the input shaft.

Remove the oil pump drive rotor from the input shaft.

Remove the 2 straight pins.

• NOTICE:

• Do not drop the straight pins.

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

Using a screwdriver, pry out the oil seal from the oil pump plate.

• NOTICE:

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

• HINT:

• Tape the screwdriver tip before use.

Using SST and a hammer, release the staked part of the nut.

• SST
• 09930-00010(09931-00010,09931-00020)

• NOTICE:

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

• SST
• 09330-00021

Using SST, remove the companion flange.

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

Remove the O-ring from the companion flange.

Using SST and a press, remove the transfer output shaft dust deflector.

• SST
• 09950-00020
  09950-60010(09951-00340,09951-00470,09952-06010)
  09950-70010(09951-07100)

• NOTICE:

• Do not drop the front output shaft companion flange sub-assembly.

Using SST, remove the front transfer case oil seal.

• SST
• 09308-10010
  09950-40011(09957-04010)

• NOTICE:

Using SST and a hammer, release the staked part of the nut.

• SST
• 09930-00010(09931-00010,09931-00020)

• NOTICE:

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

• SST
• 09330-00021

Using SST, remove the companion flange.

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

Remove the O-ring from the companion flange.

Using SST, tap out the oil seal.

• SST
• 09308-00010

• NOTICE:

• Be careful not to damage the oil seal and rear transfer case contact surface.

Remove the plug, compression spring and pin.

Using a 6 mm hexagon wrench, remove the plug.

Remove the 14 bolts.

Remove the rear transfer case.

• HINT:

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

Remove the needle roller bearing and spacer from the output shaft.

Using 2 screwdrivers and a hammer, tap out the 4 shift fork shaft snap rings.

Remove the bolt. Then remove the No. 2 gear shift fork together with the high and low clutch sleeve from the shift actuator.

Remove the No. 1 gear shift fork bolt.

Remove the 3 bolts.

Remove the shift actuator and No. 1 gear shift fork from the rear transfer case.

• NOTICE:

• Take care not to drop the No. 1 gear shift fork.

Remove the O-ring from the shift actuator.

Using a snap ring expander, expand the snap ring as shown in the illustration.

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

Remove the output shaft and driven sprocket from the drive chain.

• NOTICE:

• Do not drop the output shaft washers.

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

Remove the clutch sleeve from the output shaft.

Using a screwdriver, remove the snap ring.

Using SST, remove the bearing.

• SST
• 09308-00010

Remove the 3 bolts and oil separator.

Remove the O-ring from the oil separator.

Remove the magnet from the oil separator.

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

Using a snap ring expander, expand the snap ring as shown in the illustration. Then remove the input shaft from the front transfer case.

Using a screwdriver, remove the snap ring. Then remove the low planetary ring gear from the front transfer case.

Using a snap ring expander, remove the snap ring from the front transfer case.

Using a screwdriver, remove the snap ring. Then remove the bearing from the front transfer case.

Remove the synchronizer ring from the input shaft.

Remove the seal ring from the input shaft.

Using a snap ring expander, remove the snap ring.

Using SST and a press, press out the bearing.

• SST
• 09555-55010
  09950-60010(09951-00490)
  09950-70010(09951-07100)

• NOTICE:

• Be careful not to drop or damage the input shaft, low planetary gear and low planetary gear bearings.

• HINT:

• When the bearing is removed, the input shaft, low planetary gear, and 2 low planetary gear bearings will come off.

Using SST, remove the bush.

• SST
• 09387-00041(09387-01021,09387-01030,09387-01040)

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

• SST
• 09950-70010(09951-07150)
  09950-60010(09951-00300)

Remove the 2 output shaft washers from the output shaft.

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

Remove the output shaft spacer from the output shaft.

Remove the seal ring from the output shaft spacer.

Remove the straight pin from the output shaft.

Remove the center differential case from the output shaft.

for Manual Transmission:

Using a snap ring expander, remove the snap ring.

for Manual Transmission:

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

Using SST, remove the needle roller bearing.

• SST
• 09308-00010

Using SST, remove the needle roller bearing.

• SST
• 09387-00041(09387-01021,09387-01030,09387-01040)

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

Remove the output shaft spacer from the output shaft.

Remove the straight pin from the output shaft.

Remove the drive sprocket from the output shaft.

Remove the bearing from the output shaft.

Using SST and a press, press out the bearing.

• SST
• 09527-10011

• NOTICE:

• Be careful not to drop or damage the output shaft.

Remove the needle roller bearing from the output shaft.