Steps 36-70

Transfer Case Disassemble (Continued)





37. Use a plastic mallet in order to remove the rear output shaft from the center case.





38. Use J22912-01 and a press arbor in order to remove the rear output shaft front bearing from the rear output shaft.





39. Using a plastic mallet, remove the front output shaft and the bearings (1) from the center case.





40. Remove the following components from the center case:
^ One bolt (1)
^ The case gutter





41. Use J 26941 with J 23907 in order to remove the front output shaft oil seal from the center case.





42. Using J 26941 and a hammer, remove the front output shaft needle bearing from the center case.





43. Use J 22912-01 with J 34844 and a press arbor in order to remove the front output shaft bearings from the front output shaft.





44. Loosen the center bearing snap ring within the input gear. You cannot remove this snap ring at this time.





45. Using a plastic mallet, remove the input gear assembly from the front case.





46. Using J 26941 with J 23907, remove the input gear oil seal from the front case.





Important: During gear assembly removal, the bearing may move, binding the snap ring in its groove. Apply light pressure with the mallet in order to slide the bearing back to its original position before you attempt to remove the snap ring.

47. Using snap ring pliers, remove the side bearing snap ring (1) from the input gear.





48. Use J 22912-01 with J 28406 and a press arbor in order to remove the input gear bearing from the input gear.
49. Remove the center bearing snap ring from the input gear.





50. Remove one roll pin from the reduction shift fork.
51. Remove the reduction roll fork from the reduction shift shaft.
52. Remove the following components from the front drive shift shaft:
^ The two E-clips (6)
^ The shaft stop washer (5)
^ The front drive shift fork (4)
^ The front drive fork spring (3)

Important: Careful cleaning of the component mating surfaces will ensure proper case sealing.

53. Clean the following components with solvent and dry thoroughly:
^ The front case
^ The rear case
^ The center case
54. Clean all of the internal components with solvent and dry thoroughly.
55. Inspect the following components for cracks or porosity:
^ The front case
^ The rear case
^ The center case
^ The gearshift lever case
^ Replace as necessary.
56. Inspect the drive teeth and the clutching teeth of all of the gears and sprockets for the following conditions:
^ Broken teeth
^ Chipped teeth
^ Gear clash damage
57. Inspect the shift shafts and the forks for the following conditions:
^ Excessive wear
^ Distortion
^ Replace as necessary
58. Inspect each ball bearing for smooth rotation. If the rotation is abnormal, replace the ball bearing.
59. Inspect the needle bearing and the bearing contacting surface for damage. Replace as required.
60. Inspect the gear tooth surface and the shift mechanism. Correct an abnormal mechanism or replace as required.
61. Inspect the drive chain and the sprockets for abnormal wear or damage. Replace as required.
62. Inspect the oil seal for leakage and inspect the oil seal lip for excessive hardness. inspect the corresponding surface of the shaft where the oil seal lip contacts. Correct an abnormal condition or replace as required.
63. Inspect the gear tooth surface of the speedometer drive gear. Replace a damaged gear.





64. Inspect the clutch hubs (1) and the sleeves (2) for the following conditions:
^ Poor fit
^ Cracked teeth (3)
^ Broken teeth
^ Replace as necessary





65. Inspect the locating springs for the following conditions:
^ Weakness
^ Distortion
^ Replace as necessary
66. Use J 26900-5 in order to measure each locating spring.
^ Standard spring length is 19.5 mm (0.768 inch).
If a spring length measures below 18.0 mm (0.709 inch), replace the springs as necessary.





67. Use a feeler gage in order to measure the shift fork-to-clutch sleeve clearance.
^ The maximum shift fork-to-clutch sleeve clearance is 1.0 mm (0.039 inch).
If the clearance is greater than 1.0 mm (0.039 inch), replace the shift fork and the clutch sleeve as necessary.





68. Assemble the following components:
^ The synchronizer outer ring (4)
^ The inner ring (2)
^ The cone (3)
69. Measure the step difference (1) between the outer ring and the inner ring.
^ The standard difference between the inner ring and the outer ring is 1.0 - 1.4 mm (0.039 - 0.055 inch).





70. Measure the key slot width (2) in the synchronizer outer ring (1) and inspect each chamfered tooth of the gear and the synchronizer ring. If necessary, replace the outer ring.
^ The maximum slot width in the outer ring is 10.1 mm (0.397 inch).