Transfer Assembly Disassembly

Detach the clamp and remove the hose.

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

HINT:

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

for RA61F:
Remove the O-ring from the transfer bearing retainer sub-assembly RH.

for A750F, AC60F, G52F, R150F:
Using a screwdriver and hammer, remove the transfer bearing retainer oil seal RH from the transfer bearing retainer sub-assembly RH.

for RA61F:
Using a screwdriver and hammer, remove the 2 transfer bearing retainer oil seals RH from the transfer bearing retainer sub-assembly RH.

Remove the 4 bolts and transfer case cover sub-assembly.

Remove the breather oil deflector.

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

Using SST to hold the front output shaft companion flange sub-assembly, 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, tap out the oil seal.

SST

09308-00010

NOTICE:

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

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, tap out the oil seal.

SST

09308-00010

NOTICE:

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

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 washers.

Remove the collar.

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.

Remove the bolt, No. 2 gear shift fork, and high and low clutch sleeve.

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

Remove the bolt, center differential lock fork and front drive clutch sleeve.

Mount the rear transfer case in a vise.

Using a snap ring expander, remove the snap ring.

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

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

Using SST and a press, remove the driven sprocket bearing.

SST

09555-55010

NOTICE:

Be careful not to drop or damage the driven sprocket.

Using SST and a press, remove the transfer input gear radial ball bearing.

SST

09555-55010

NOTICE:

Be careful not to drop or damage the driven sprocket.

Using 2 screwdrivers and a hammer, tap off the 2 snap rings.

Remove the 3 bolts and transfer shift actuator assembly.

Remove the O-ring from the transfer shift actuator assembly.

Remove the filler plug and gasket.

Remove the drain plug and gasket.

Remove the 3 bolts and oil separator.

Remove the 3 bolts and oil pump body.

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

NOTICE:

Be careful not to damage the oil pump body.

Remove the transfer oil pump gear.

Using a snap ring expander, remove the snap ring.

Remove the low planetary gear together with the input shaft.

Remove the transfer output shaft spacer.

Remove the needle roller bearing.

Using a snap ring expander, remove the snap ring.

Remove the input gear stopper.

Remove the ball.

Remove the washer.

Remove the transfer input shaft.

Remove the thrust bearing race.

Remove the bearing.

Remove the 2 seal rings.

Using a snap ring expander, remove the snap ring.

Using SST and a press, remove the input shaft bearing.

SST

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

NOTICE:

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

Using a screwdriver, remove the snap ring.

Remove the low planetary gear spline piece.

Using SST, remove the low planetary gear bearing.

SST

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

NOTICE:

Make sure SST fits securely in the space between the bearing and low planetary gear.

Using a snap ring expander, remove the snap ring.

Remove the spacer.

Remove the ball.

Remove the center differential case.

Remove the transfer clutch hub.

Remove the needle roller bearing.

Remove the washer.

Using SST and a press, remove the bearing.

SST

09555-55010

Remove the output shaft spacer.

Remove the transfer drive sprocket.

Remove the bearing.

Remove the washer.

Remove the transfer case plug.

Remove the spring.

Remove the pin.

Using a screwdriver, remove the snap ring.

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