Transfer Assembly Disassembly

Using SST, remove the transfer indicator switch and gasket.

SST

09817-16011

Using SST, remove the transfer indicator switch and gasket.

SST

09817-16011

Using SST, remove the transfer indicator switch and gasket.

SST

09817-16011

Using a pin punch and hammer, remove 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 4 bolts and transfer case cover sub-assembly.

Remove the 5 bolts and transfer bearing retainer sub-assembly.

HINT:

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

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

NOTICE:

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

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 front output shaft companion flange sub-assembly.

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, tap out the transfer case oil seal.

SST

09308-00010

NOTICE:

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

Remove the rear output shaft companion flange sub-assembly in the same way as the front output shaft companion flange.

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.

Using SST, tap out the oil seal.

SST

09308-00010

NOTICE:

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

Disconnect the sensor connector.

Remove the bolt and speedometer sensor from the transfer.

Remove the O-ring from the speedometer sensor.

Remove the 5 bolts and extension housing.

HINT:

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

Remove the 2 transfer output shaft washers.

Remove the transfer speedometer drive gear and ball.

Remove the 12 bolts and clamp.

Remove the rear transfer case.

HINT:

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

Using a hexagon wrench, remove the 2 plugs.

Using a magnet hand, remove the 2 springs and 2 balls from the holes.

Mount the rear transfer case in a vise.

NOTICE:

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

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

Hold the front transfer drive shift fork shaft in place by hand when removing the pin punch.

Remove the front transfer drive shift fork shaft, stopper, compression spring, No. 1 gear shift fork and shift shaft stopper.

Using a magnet hand, remove the straight pin.

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

Using a snap ring expander, remove the snap ring.

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

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

Using SST and a press, press out the transfer driven sprocket bearing.

SST

09555-55010

NOTICE:

Be careful not to drop or damage the driven sprocket.

Using SST, a press and a steel bar, press out the transfer input gear radial ball bearing.

SST

09555-55010

NOTICE:

Be careful not to damage the driven sprocket.

Remove the filler plug and gasket.

Remove the drain plug and gasket.

Remove the 3 bolts and transfer oil separator sub-assembly.

Remove the 3 bolts and transfer oil pump body sub-assembly.

Using a screwdriver with its tip wrapped with protective tape, pry out the transfer oil pump body O-ring from the oil pump body.

NOTICE:

Be careful not to damage the oil pump body.

Remove the nut and transfer oil pump gear.

Remove the front transfer drive clutch synchronizer ring from the transfer input shaft.

Using a snap ring expander, remove the snap ring.

Remove the transfer low planetary gear assembly together with the transfer input shaft.

Remove the transfer case plug, compression spring and pin from the front transfer case.

Using a screwdriver with its tip wrapped with protective tape, pry out the snap ring.

NOTICE:

Be careful not to damage the front transfer case.

Remove the transfer low planetary ring gear from the front transfer case.

Using a screwdriver and hammer, tap out the 2 transfer case oil seals.

NOTICE:

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

Using a screwdriver with its tip wrapped with protective tape, pry out the snap ring.

NOTICE:

Be careful not to damage the transfer low planetary gear assembly.

Remove the transfer low planetary gear spline piece from the transfer low planetary gear assembly.

Using a snap ring expander, remove the transfer input gear stopper shaft snap ring.

Remove the transfer input gear stopper.

Using a magnet hand, remove the transfer input gear stopper ball from the transfer input shaft.

Remove the manual transfer planetary carrier washer.

Remove the transfer input shaft, transfer low planetary gear bearing and No. 1 transfer thrust bearing race from the transfer low planetary gear assembly.

Remove the 2 No. 1 transfer input shaft seal rings from the transfer input shaft.

Using a snap ring expander, remove the snap ring.

Using SST and a press, press out the transfer input shaft bearing.

SST

09555-55010
09950-70010(09951-07150)
09950-60020(09951-00750)

NOTICE:

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

Using SST, remove the transfer low planetary gear bearing.

SST

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

NOTICE:

Hook SST securely between the bearing and transfer low planetary gear.

Using a snap ring expander, remove the snap ring.

Remove the high and low clutch sleeve.

for Manual Transmission:
Remove the 2 shifting key springs and 3 shifting keys.

Using a press, press out the transfer clutch hub.

NOTICE:

Be careful not to drop or damage the rear transfer output shaft.

for Manual Transmission:
Using a screwdriver and hammer, remove the key retainer from the rear transfer output shaft.

Using SST and a press, press out the rear transfer output shaft radial ball bearing from the rear transfer output shaft.

SST

09555-55010

NOTICE:

Be careful not to drop or damage the rear transfer output shaft.

Remove the spacer and ball.

Remove the transfer drive sprocket sub-assembly together with the front drive clutch sleeve.

Remove the needle roller bearing.

Remove the front drive synchronizer ring.

Remove the front drive clutch sleeve, 2 shifting key springs and 3 shifting keys from the transfer drive sprocket sub-assembly.