Disassemble

1. Raise vehicle and drain oil from transfer case.
2. Mark transfer case front and rear output yokes, then propeller shaft yokes for assembly alignment.
3. Disconnect speedometer cable and vacuum switch hoses.
4. Disconnect shift lever from operating lever.
5. Support transmission, then remove crossmember.
6. Disconnect propeller shafts and secure to frame rails. Do not let shafts hang free.
7. Remove transfer case to transmission attaching nuts, then slide transfer case rearward and remove.
8. Remove all gasket material from transmission surfaces.
9. Remove fill and drain plugs, then mark output shaft and transfer case yoke for assembly alignment reference.
10. Disconnect propeller shaft and secure shaft to underside of vehicle.
11. Remove front yoke retaining nut, then the yoke and seal. The yoke seal, washer and nut are not reusable and must be discarded at this time.
12. Remove retainer seal, using a suitable tool if seal or bushing is to be replaced.
13. Install a new seal if necessary and remove speedometer gear from rear retainer, then mark rear retainer for assembly alignment reference.

Rear Retainer Removal:

14. Remove rear retainer attaching bolts, then remove retainer, using a screwdriver to pry it free.
15. Remove speedometer drive gear, if necessary and completely clean off old RTV sealant.
16. If retainer and bearing are to be replaced, remove bearing retainer snap ring and bearing.

Rear Case Removal:

17. Remove lower snap ring from shaft, then pry rear case loose, using screwdrivers on both sides, then remove rear case.
18. Remove mode spring, oil pickup screen and driven sprocket retaining snap ring.

Sprocket & Drive Chain Removal:

19. Remove driven sprocket from front output shaft and drive chain.

Range Fork & Hub Removal:

20. Remove front output shaft, then the range fork and hub.
21. Remove low range gear, then the low range gear snap ring.

Input Gear Snap Ring Removal:

22. Remove input shaft bearing retainer, then the input gear snap ring.

Input Gear Bearing Removal:

23. Remove input gear bearing, using bearing removal tool Nos. C-4171 and C-4210, or equivalents.
24. Remove synchronizer snap ring from mainshaft, then remove synchronizer assembly.

Drive Sprocket Needle Bearing Replacement:

25. Remove drive sprocket, then using bearing removal tool No. C-4697-1, or equivalent, remove both drive sprocket needle bearings.

Front & Rear Bearing Position:

26. Replace drive sprocket needle bearings, using bearing removal tool No. C-4697-1, or equivalent.

Mainshaft Pilot Bearing Removal:

27. Pull mainshaft pilot bearing using tool No. MD-998346, or equivalent.

Mainshaft Pilot Bearing Installation:

28. Install mainshaft pilot bearing using tool Nos. C-4171 and 5065, or equivalents.

Rear Output Seal Replacement:

29. Remove rear output seal using tool No. C-4613, or equivalent.

Rear Output Bearing Removal:

30. Remove rear output bearing using tool Nos. C-4610 and C-4171, or equivalents.
31. Remove front output shaft front bearing.

Front Output Shaft Rear Bearing Removal:

32. Remove front output shaft rear bearing using tool Nos. L-4518-1 and L4454-1, or equivalents.
33. Clean and inspect all parts, inspecting condition of all needle, roller, ball and thrust bearings.
34. Ensure all bearing bores in case are not pitted or scored. Replace any parts that show excessive wear, distortion or damage.
35. Reverse procedure to assemble. Use Permatex No. 3 sealer or equivalent on transmission to transfer case gasket.