Transfer Case: Disassembly
- Remove 4WD switch and steel ball. Remove 4WD low switch and steel ball (if equipped). Remove speedometer driven gear assembly. Remove 5 bolts and remove gearshift lever housing. Remove gearshift lever spring bolt, washer, spring, steel ball and pin. See Fig 2 .
- Using hammer and punch, drive out shift yoke roll pin. Slide shift yoke rearward and remove from shift yoke shaft. Remove 15 rear case-to-center case bolts. Using Case Separator (J-37637), separate rear case from center case. Using magnet, remove shift yoke shaft roll pin from bottom of transfer 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 and speedometer drive gear. Carefully remove speedometer drive gear ball from rear output shaft. Remove rear output shaft rear bearing "C" clip from output shaft. Using Pitman Arm Puller (J-8433) and Output Shaft Bearing Puller Adapter (J-37756), remove rear bearing from rear output shaft.
- Remove drive sprocket bushing and needle bearing from rear output shaft. DO NOT lose steel ball when removing drive sprocket bushing. Remove 2 bolts, and remove synchronizing plate. Remove drive sprocket and drive chain. Using Needle Bearing Puller (J-26941) and slide hammer, remove rear output shaft oil seal from rear case. Remove oil guide from front case.
- Using Needle Bearing Puller (J-26941) and hammer, remove rear output shaft needle bearing from rear case. Remove bolt and washer, and remove case plate from front case. Remove 9 front case-to-center case bolts. Separate front case from center case. Remove countershaft assembly from center case. Remove washers and 2 washer lock balls from countershaft. Remove counter gear, 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. Inspect countershaft friction gear and "O" ring for damage and excessive wear, and replace as necessary.
- Remove 2 rubber plugs, 2 locating screws, 2 locating springs and 2 shift shaft locating balls from center case. Remove reduction shift shaft, shift fork and clutch sleeve from rear output shaft in front of center case.NOTE: Examine reduction clutch sleeve and hub, and front drive clutch sleeve and hub for alignment marks. Place alignment marks on components if none are present.
- Remove front drive shift shaft, shift fork, clutch sleeve and clutch hub from rear output shaft in rear of center case. Remove shift shaft interlock ball and spring from center case passage. See Fig 3 . Remove "C" clip from rear output shaft and remove reduction clutch hub, low output gear and needle bearing. Using plastic mallet, drive output shaft from center case. Using press and appropriate bearing splitter, press front bearing off rear output shaft. Using plastic mallet, remove front output shaft with bearings from center case.
- Remove bolt and remove case oil gutter from center case. Using Needle Bearing Puller (J-26941) and slide hammer, remove front output shaft oil seal and needle bearing from center case. Using press and appropriate bearing splitter, remove bearings from front output shaft. Loosen center bearing snap ring within input gear. Snap ring cannot be completely removed at this time. Using plastic mallet, drive input gear with bearing from front case.
- Using Needle Bearing Puller (J-26941) and slide hammer, remove input gear oil seal from front case. Remove bearing snap from input gear. Using Bearing Installer (J-28406), appropriate bearing splitter and press, remove bearing from input gear. Remove roll pin from reduction shift fork. Remove reduction shift fork from shift shaft. Remove 2 "E" clips, shaft stop washer, shift fork and shift fork spring from front drive shift shaft.