Transfer Assembly: Disassembly

1. Remove the bolt and driven gear.

1. Remove the 4 bolts and motor actuator.

Fig 1: Identifying Motor Actuator

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1. Using a T40 "torx" socket, remove the screw plug.

Fig 3: Identifying Screw Plug

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1. Using a magnetic finger, remove the spring.

1. Using a magnetic finger, remove the ball.

1. Remove the 3 indicator switches and 3 gaskets.

1. Remove the 6 bolts and extension housing.

Fig 4: Identifying Front Transfer Extension Housing

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HINT:

If necessary, tap the extension housing lightly with a plastic-faced hammer.

1. Using 2 screwdrivers and a hammer, tap out the 3 snap rings from the No. 2 shift fork shaft.
   Fig 6: Identifying Snap Rings

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2. Separate the No. 2 shift fork shaft and No. 2 shift fork.

1. Remove the 9 bolts and extension housing.

Fig 7: Identifying Rear Transfer Extension Housing

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HINT:

If necessary, tap the extension housing lightly with a plastic-faced hammer.

1. Remove the adjusting shims.

1. Remove the 2 bolts and oil strainer.

Fig 8: Identifying Oil Strainer Assembly

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1. Remove the 5 bolts.
   Fig 9: Identifying Bolts

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2. Using a brass bar and hammer, tap the case cover and remove it.

Fig 10: Identifying Case Cover

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1. Using a snap ring expander, remove the snap ring from the rear case.
   Fig 11: Removing Snap Ring From Rear Case

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2. Remove the 8 bolts.
3. Using a brass bar and hammer, tap the rear case and separate it.

Fig 12: Identifying Rear Case

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1. Remove the 2 bearing races from the rear case.

Fig 13: Identifying Bearing Race

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1. Using a plastic-faced hammer, remove the input shaft from the front case.

Fig 14: Identifying Input Shaft

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1. Remove the idler gear with center differential, No. 1 shift fork shaft and No. 1 shift fork from the front case.

Fig 15: Identifying Idler Gear With Center Differential, No 1 Shift Fork Shaft And No 1 Shift Fork

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1. Using a pin punch and hammer, tap out the slotted spring pin.
   Fig 16: Identifying Spring Pin

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2. Separate the No. 1 shift fork and No. 1 shift fork shaft.

1. Remove the nut and washer from the outer shift lever.
2. Using a brass bar, hammer and socket wrench, tap out the lever lock pin.
   Fig 17: Identifying Lever Lock Pin

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3. Remove the outer shift lever, washer and inner shift lever from the front case.

1. Using a screwdriver, pry out the oil seal from the front case.

Fig 18: Identifying Inner Shift Lever Oil Seal

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1. Using SST and a hammer, tap out the oil seal.

Fig 19: Identifying Input Shaft Oil Seal

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SST 09316-60011 (09316-00011) 

1. Remove the bolt and oil receiver from the front case.

Fig 20: Identifying Oil Receiver

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1. Using SST, remove the bearing race (for the idler gear).
   Fig 21: Identifying Bearing Race (For Idler Gear)

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   SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010), 09950-60010 (09951-00320) 

2. Using a brass bar and hammer, tap out the bearing race (for the output shaft) from the front case.

Fig 22: Removing Bearing Race (For Output Shaft) From Front Case

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