Part 2

SHIFT FORKS AND MAINSHAFT










1. Loosen detent plug (2).
2. Remove detent plug (2), spring (3), and plunger (4). Note that the plug has an O-ring seal. Remove and discard this seal.










3. Remove the front output shaft (1) snap-ring (2).










4. Remove front output shaft (2) from bearing in the front case (1).










5. Pull mainshaft assembly (2) out of input gear, mode sleeve, and front case (1).










6. Remove mode fork (2), mode sleeve (1), and shift rail as assembly. Note which way the sleeve fits in the fork (long side of sleeve goes to front).










7. Remove range fork retaining ring.
8. Remove range fork (2) and hub (1) as an assembly. Note fork position for installation reference.










9. Remove shift sector (1).










10. Remove the shift sector o-ring (2) from the front housing (1).

MAINSHAFT










1. Remove the drive sprocket (3) retaining ring (2) from the output shaft (1).










2. Remove the drive sprocket (3) thrust washer (2) from the output shaft (1).










3. Remove drive sprocket (2) from the output shaft (1).










4. Remove the clutch gear (2) from the output shaft (1).










5. Remove the sprocket hub (2) from the output shaft (1).










6. Remove the mode hub retaining ring (2) from the output shaft (1).










7. Remove the mode hub (2) from the output shaft (1).

INPUT AND PLANETARY GEAR










1. Remove input gear seal with suitable screw and slide hammer.
2. Remove input gear (1) retaining ring (2) with heavy duty snap-ring pliers.










3. Place front case in horizontal position. Then remove input gear and low range gear as an assembly (2). Tap gear out of bearing with plastic mallet, if necessary.

INPUT AND PLANETARY GEAR










1. Remove snap-ring (1) that retains input gear in low range gear.










2. Remove retainer (3).










3. Remove front tabbed thrust washer (1).










4. Remove input gear (1).










5. Remove rear tabbed thrust washer (2) from low range gear (1).