Tools Required

1. Remove the following components from the rear case:

•	The four-wheel drive switch

•	The steel ball

2. Remove the following components from the rear of the case (if equipped):

•	The four-wheel drive low switch

•	The steel ball

•	(If needed, use a magnet in order to remove the steel ball from the case.)

3. Remove the following components from the rear case:

•

One bolt

•	The speedometer driven gear case




4. Remove the following components from the rear case:

•	The 5 bolts

•	The gearshift lever case




5. Remove the following components from the rear case (6):

•	The select return spring bolt (1)

•	The washer (2)

•	The select return spring (3)

•	The select return ball (4)

•	The select return pin (5)





Important: Driving the reduction shift yoke roll pin down will cause the pin to fall down into the transfer case assembly. Use a magnet during the removal of the reduction shift yoke roll pin after removing the rear case.

6. Use a standard drift punch and a hammer in order to remove the reduction shift yoke roll pin from the reduction shift yoke.
7. Slide the reduction shift yoke rearward. Pull the reduction shift yoke off the reduction shift shaft and out of the rear case.
8. Remove the 15 rear case bolts.



9. Separate the rear case from the center case using a J 37637 .
10. Remove the selective shim from the top of the rear output shaft rear bearing.



11. Use J 34757 in order to remove the following components from the rear output shaft:

•	The speedometer drive gear C-clip

•	The speedometer drive gear




12. Use J 34757 in order to remove the rear output shaft rear bearing C-clip from the rear output shaft.



13. Use J 8433 with J 37756 in order to remove the rear output shaft rear bearing from the rear output shaft.




Important: Do not lose the rear output shaft washer ball underneath the drive sprocket bushing during the sprocket bushing removal.

14. Remove the following components from the rear output shaft:

•	The drive sprocket bushing

•	The drive sprocket needle bearing




15. Remove the following drive components from the rear output shaft and the front output shaft:

•	The drive sprocket

•	The drive chain

•	The rear output shaft washer ball




16. Use J 26941 with J 23907 in order to remove the rear output shaft oil seal from the rear case.



17. Use J 26941 with J 23907 in order to remove the rear output shaft needle bearing from the rear case.



18. Remove the following components from the front case:

•	One bolt (2)

•	The countershaft case plate (1)




19. Remove the 9 front case bolts from the front case.



20. Separate the front case from the center case (1).
21. Remove the countershaft assembly (3) from the center case.




Important: Do not lose the countershaft washer balls which come out from between the countershaft (9) and the countershaft washers (1,7).

22. Remove the following components from the countershaft (9):

•	The countershaft washers (1,7)

•	The washer balls (3)

23. Remove the following components from the countershaft:

•	The counter gear (6)

•	The countershaft needle bearings (4,8)

•	The countershaft spacer (5)

24. Inspect the countershaft friction ring for excessive wear or damage. Replace as necessary.
25. Inspect the countershaft O-ring for cuts or other damage. Replace as necessary.

Important: Do NOT remove either the countershaft friction ring (10) or the O-ring (2) unless absolutely necessary. If you remove either one, replace with new components.

26. Remove the countershaft O-ring from the countershaft.



27. Use J 39497 and a press arbor (2) in order to remove the countershaft friction ring (1) from the countershaft (3).



28. Remove the following components from the center case:

•	The 2 rubber plugs (1)

•	The 2 locating screws (4)

•	The 2 washers

•	The 2 locating springs (3)

•	The 2 locating balls (2)





Important: Observe the alignment marks on the following components in order to ensure correct alignment during assembly:

•	The reduction clutch sleeve and hub

•	The front drive clutch sleeve and hub

If no alignment marks are present, scribe new marks on these components.
29. Remove the following components from the rear output shaft, in front of the center case:

•	The reduction shift shaft (2)

•	The reduction shift fork (1)

•	The reduction clutch sleeve (3)

30. Remove the following components from the rear output shaft, in the rear of the center case:

•	The front drive shift shaft

•	The front drive shift fork

•	The front drive clutch sleeve

•	The front drive clutch hub

31. Remove the interlock ball from the center case passage.
32. Use J 34757 in order to remove the reduction hub C-clip (3) from the rear output shaft.



33. Remove the following components from the rear output shaft.

•	The reduction clutch hub (3)

•	The low output gear (2)

•	The low output gear needle bearing (1)




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



35. Use J 22912-O1 and a press arbor in order to remove the rear output shaft front bearing from the rear output shaft.



36. Use a plastic mallet in order to remove the following components from the center case:

•	The front output shaft

•	The bearings




37. Remove the following components from the center case:

•

One bolt

•	The case gutter




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



39. Use J 26941 with J 23907 in order to remove the front output shaft needle bearing from the center case.



40. Use J 22912-O1 with J 34844 and a press arbor in order to remove the front output shaft bearings from the front output shaft.



41. Remove the input gear bearing C-clip from the input gear.



42. Use a plastic mallet in order to remove the input gear from the front case.



43. Remove the following components from the rear case:

•

One bolt

•	The oil guide




44. Use J 26941 with J 23907 in order to remove the input gear oil seal from the front case.



45. Remove the input gear snap ring from the input gear.



46. Use J 22912-O1 with J 28406 and a press arbor in order to remove the input gear bearing from the input gear.
47. Remove one roll pin from the reduction shift fork.
48. Remove the reduction roll fork from the reduction shift shaft.
49. Remove the following components from the front drive shift shaft:

•	The two C-clips

•	The shaft stop washer

•	The front drive shift fork

•	The front drive fork spring

50. Clean the following front case components thoroughly with clean solvent:

Thoroughly dry the components.

•	The front case

•	The rear case

•	The center case

•	Ensure proper case sealing to all of the case component mating surfaces.

51. Clean all of the internal components with solvent.

Thoroughly dry the components.

52. Inspect the following components for cracks or porosity:

•	The front case

•	The rear case

•	The center case

•	The gearshift lever case

•	Replace as necessary.

53. 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

54. Inspect the shift shafts and the forks for the following conditions:

•	Excessive wear

•	Distortion

•	Replace as necessary

55. Inspect the clutch hubs and the sleeves for the following conditions:

•

Poor fit

•	Cracked teeth

•	Broken teeth

•	Replace as necessary

56. Inspect the locating springs for the following conditions:

•

Weakness

•	Distortion

•	Replace as necessary




57. Use J 26900-5 in order to measure each locating spring.

Measurement
Standard spring length is 19.5 mm (0.768 in).

If a spring length measures below 18.0 mm (0.709 in), replace the springs as necessary.




58. Use a feeler gage in order to measure the shift fork-to-clutch sleeve clearance.

Measurement
The maximum shift fork-to-clutch sleeve clearance is 1.0 mm (0.039 in).

If the clearance is greater than 1.0 mm (0.039 in), replace the shift fork and the clutch sleeve as necessary.