Transfer Assembly Disassembly

Remove the indicator switches and gaskets.

HINT:

Indicator switch:

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

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

Remove the 5 bolts and bearing retainer.

HINT:

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

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.

Remove the 4 bolts and retainer.

Remove the 4 bolts and case cover.

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

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)

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.

Using SST, remove the lock nut and 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)

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.

Disconnect the sensor connector.

Remove the bolt and sensor with driven gear.

Remove the 5 bolts and extension housing.

HINT:

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

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

NOTICE:

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

Remove the 2 washers and drive gear.

Remove the 12 bolts and 2 clamps.

Remove the rear case.

HINT:

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

Mount the rear case in a vise.

NOTICE:

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

Using a pin punch and hammer, drive out the slotted spring pin.

Using a hexagon wrench, remove the No. 1 plug.

Using a magnetic finger, remove the spring and ball from the hole.

Remove the No. 2 gear shift fork and high and low shift fork shaft.

Using a magnetic finger, remove the straight pin.

Automatic transmission:
Remove the high and low clutch sleeve.

Manual transmission:
Remove the high and low clutch sleeve, 3 shifting keys and 2 No. 1 springs.

Mount the rear case in a vise.

NOTICE:

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

Using a pin punch and hammer, drive out the slotted spring pin.

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

Using a hexagon wrench, remove the No. 2 plug.

Using a magnetic finger, remove the spring and ball from the hole.

Remove the center differential lock fork, shift shaft stopper, 2 springs, 3 stoppers, front drive shift shaft and front drive clutch sleeve.

Mount the rear case in a vise.

NOTICE:

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

Using a snap ring expander, remove the snap ring.

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

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

Using a press, press out the bearing.

NOTICE:

Be careful not to drop or damage the driven sprocket.

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

SST

09555-55010

NOTICE:

Be careful not to drop or damage the driven sprocket.

Remove the filler plug (for filler) and gasket.

Remove the drain plug (for drain) and gasket.

Remove the 3 bolts and separator.

Remove the 3 bolts and pump body.

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

NOTICE:

Be careful not to damage the pump body.

Remove the nut and pump gear.

Using a snap ring expander, remove the snap ring.

Remove the low planetary gear with the input shaft.

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

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

NOTICE:

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

Using a snap ring expander, pry out the snap ring.

Remove the 2 seal rings.

Using a snap ring expander, remove the snap ring.

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.

Using a screwdriver, remove the snap ring.

NOTICE:

Be careful not to damage the spline piece.

Remove the spline piece.

Using SST, remove the bearing.

SST

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

NOTICE:

Hang SST securely between the bearing and low planetary gear.

Using a snap ring expander, remove the snap ring.

Using SST and a press, press out the bearing.

SST

09555-55010

Using a screwdriver, pry out the snap ring.

NOTICE:

Be careful not to damage the ring gear and front case.

Remove the ring gear from the front case.