Transfer Assembly Disassembly

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:

1. Be sure to use SST with the tapered surface facing the shaft.
   
2. Do not grind the tip of SST with a grinder, etc.
   
3. Completely loosen the staked part of the nut when removing it.
   
4. Do not damage the threads of the transfer driven sprocket.
   

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:

1. Be careful not to damage the front transfer case oil seal and front transfer case contact surface.
   
2. Apply grease to the tip of SST center bolt before use.
   

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

SST

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

NOTICE:

1. Be sure to use SST with the tapered surface facing the shaft.
   
2. Do not grind the tip of SST with a grinder, etc.
   
3. Completely loosen the staked part of the nut when removing it.
   
4. Do not damage the threads of the rear transfer output shaft.
   

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.