Disassembly

1. REMOVE BREATHER HOSE

2. REMOVE VEHICLE SPEED SENSOR DRIVEN GEAR

Remove the bolt and driven gear.

3. REMOVE MOTOR ACTUATOR

Remove the 4 bolts and motor actuator.

4. REMOVE OUTPUT GEAR FROM FRONT CASE

5. REMOVE SCREW PLUG, SPRING AND BALL

(a) Using a torx socket wrench (T40), remove the screw plug.

(b) Using a magnetic finger, remove the spring and ball.

6. REMOVE TRANSFER INDICATOR SWITCH

Remove the 3 transfer indicator switches and 3 gaskets.

7. REMOVE FRONT EXTENSION HOUSING

Remove the 6 bolts and front extension housing.

HINT: If necessary, tap the front extension housing lightly with a plastic hammer.

8. REMOVE CLUTCH SLEEVE WITH SHIFT FORK NO. 2 SHAFT AND SHIFT FORK NO. 2

9. SEPARATE SHIFT FORK NO. 2 SHAFT AND SHIFT FORK NO. 2

(a) Using 2 screwdrivers and a hammer, tap out the 3 snap rings from the shift fork No. 2 shaft.

(b) Separate the shift fork No. 2 shaft and shift fork No. 2.

10. REMOVE REAR EXTENSION HOUSING

Remove the 9 bolts and rear extension housing.

HINT: If necessary, tap the rear extension housing lightly with a plastic hammer.

11. REMOVE ADJUSTING SHIMS

12. REMOVE OIL STRAINER FROM REAR CASE

Remove the 2 bolts and oil strainer.

13. REMOVE CASE COVER

(a) Remove the 5 bolts.

(b) Using a brass bar and hammer, tap the case cover and remove it.

14. SEPARATE FRONT CASE AND REAR CASE

(a) Using a snap ring expander, remove the snap ring from the rear case.

(b) Remove the 8 bolts.

(c) Using a brass bar and hammer, tap the rear case and separate it.

15. REMOVE 2 BEARING RACES FROM REAR CASE

16. REMOVE INPUT SHAFT ASSEMBLY

Using a plastic hammer, remove the input shaft assembly from the front case.

17. REMOVE IDLER GEAR ASSEMBLY WITH CENTER DIFFERENTIAL ASSEMBLY, SHIFT FORK NO. 1 AND SHIFT FORK NO. 1 SHAFT FROM FRONT CASE

18. SEPARATE SHIFT FORK NO. 1 AND SHIFT FORK NO. 1 SHAFT

(a) Using a pin punch and hammer, drive out the slotted spring pin.

(b) Separate the shift fork No. 1 and shift fork No. 1 shaft.

19. REMOVE SHIFT OUTER LEVER AND INNER LEVER

(a) Remove the nut and washer from the shift outer lever. (b) Using a brass bar, hammer and socket wrench, tap out the lever lock pin.

(c) Remove the shift outer lever, washer and inner lever from the front case.

20. IF NECESSARY, REPLACE INNER SHIFT LEVER OIL SEAL

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

(b) Apply MP grease to the lip of a new oil seal.

(c) Using SST and a hammer, drive in a new oil seal.

SST 09950- 60010 (09951- 00270), 09950- 70010 (09951-07150)

21. IF NECESSARY, REPLACE INPUT SHAFT OIL SEAL

(a) Using SST and a hammer, drive out the oil seal.

SST 09316-6001 1 (09316-00011)

(b) Apply MP grease to the lip of a new oil seal.

(c) Using SST and a hammer, drive in a new oil seal.

SST 09316-6001 1 (09316-00011, 09316-00031)

22. REMOVE OIL RECEIVER FROM FRONT CASE

Remove the bolt and oil receiver.

23. REMOVE 2 BEARING RACES FROM FRONT CASE

(a) Using SST, remove the bearing race (for the idler gear).

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

(b) Using a brass bar and hammer, remove the bearing race (for the output shaft).