Transfer Case: Disassembly
- Remove 4WD switch and steel ball. Remove 4WD low switch and steel ball (if equipped). Remove speedometer driven gear case. Remove gear shift lever housing. Remove select return spring bolt, washer, spring, steel ball and pin.
- Drive out reduction shift yoke roll pin. Slide reduction shift yoke rearward and remove from reduction shift shaft. Remove 15 rear case-to-center case bolts. Using Case Separator (J-37637), separate rear case from center case.
- Remove and save shim from top of rear output shaft rear bearing. Using Output Shaft Ring Remover (J-34757), remove speedometer drive gear "C" clip, speedometer drive gear and rear output shaft rear bearing "C" clip. Using a 2-jaw puller with bearing splitter, remove rear 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. Using Needle Bearing Puller (J-26941) with a slide hammer, remove output shaft oil seal and needle bearing from rear case. Remove countershaft case plate from front case.
- Remove 9 front case-to-center case bolts. Using Case Separator (J-37637), separate front and center cases. Remove countershaft assembly from center case. Remove washers and washer balls from countershaft. Remove countergear, needle bearings and spacer from countershaft. 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 are present.
- Remove rubber plugs, locating screws, washers, locating springs and locating balls (2 of each) from center case. Remove reduction shift shaft together with fork and sleeve. Remove front drive shift shaft, fork and sleeve with hub from rear output shaft.
- Remove interlock ball from center case passage. Remove "C" clip from rear output shaft and remove reduction clutch hub, low output gear and needle bearing. Using a plastic hammer, drive output shaft from center case. Press bearing off shaft. Remove front output shaft with bearings from center case.
- Remove case gutter, oil seal and needle bearing from center case. Using a press, remove bearings from front output shaft. Remove input gear bearing "C" clip from front input gear. Using a plastic hammer, drive input gear from front case.
- Remove oil guide from rear case. Remove oil seal from front case. Remove 'C' clip from input gear and press bearing from input gear. Remove roll pin from reduction shift fork. Remove reduction shift fork from shift shaft. Remove 2 "C" clips, shaft stop washer, shift fork and fork spring from front drive shift shaft.