Transfer Case: Disassembly
- Remove 4WD switch and take out steel ball. Remove speedometer driven gear. Remove gear shift lever housing. Remove select return bolt and remove spring, steel ball and pin. Drive out reduction shift yoke roll pin. Remove rear case bolts and separate rear case from transfer.
- Slide reduction shift yoke rearward and pull reduction shift yoke off shaft. Separate and remove rear case from center case. Remove and save shim from top of rear output shaft rear bearing. Remove speedometer drive gear. Using 2-jaw puller with bearing splitter, remove bearing from output shaft.
- Remove sprocket bushing, needle bearing, sprocket and drive chain from rear output shaft. DO NOT lose steel ball when removing sprocket bushing. Remove countershaft retaining plate from front case. Remove front case from center case.
- Remove input gear needle bearing, countershaft washer and steel ball. Remove countergear, countergear shaft together with needle bearings, spacer, washer and steel balls from case. Do not remove countershaft friction gear or "O" ring unless necessary. If either is removed, they must be replaced with new components.NOTE: Examine reduction clutch sleeve/hub and front drive clutch sleeve/hub for alignment marks. Place marks on components if none exist.
- Remove bolt, spring and detent balls from case. Remove rubber plug. Remove reduction shift shaft together with fork and sleeve. Remove front drive shift shaft, fork and sleeve with hub from rear output shaft.
- Remove snap ring from rear output shaft and remove reduction clutch hub, output low gear and needle bearing. Using soft-faced hammer, drive output shaft from case. Press bearing off shaft. Remove oil seal from center case. Remove output front shaft with bearing using a plastic hammer.
- Remove front and rear bearing using a press. Press out needle bearing from center case. Remove oil seal from rear case and press out needle bearing. Remove snap ring from front input gear and drive out gear from case.
- Remove snap ring from input gear and press bearing from input gear. Compress spring on front drive fork shaft to remove "C" clip, fork and spring. Remove oil gutter and oil guide from case.