Part 2

SHIFT FORKS AND MAINSHAFT










1. Shift transfer case into NEUTRAL.
2. Remove nut that retains the shift lever to sector shaft. Then remove shift lever (3)(Figure 17) and spacer from the shaft.
3. Remove the sector support (2) with Socket.










4. Remove the transfer case position sensor or switch (2)(Figure 18) from the front case half (1).










5. Loosen detent plug (2)(Figure 19).










6. Remove detent plug (2), spring (3), and plunger (4)(Figure 20). Note that the plug has an O-ring seal. Remove and discard this seal.










7. Using a screw mounted in a slide hammer, remove the front output shaft seal.
8. Remove the front output shaft snap-ring (2)(Figure 21).










9. Remove front output shaft (2) from bearing in the front case (1)(Figure 22).










10. Pull mainshaft assembly (2)(Figure 23) out of input gear, mode sleeve, and case.










11. Remove mode fork (2), mode sleeve (3), and shift rail (1) as assembly (Figure 24). Note which way the sleeve fits in the fork (long side of sleeve goes to front or the points on the sleeve teeth go to the rear of case).










12. Remove range fork (2)(Figure 25) and hub (1) as an assembly. Note fork position for installation reference.










13. Remove shift sector (1)(Figure 26).

MAINSHAFT










1. Remove the clutch gear (2)(Figure 27) from the output shaft (1).










2. Remove the mode hub retaining ring (3)(Figure 28) from the mainshaft (1).










3. Remove the mode hub (2)(Figure 29) from the mainshaft (1).










4. Remove the drive sprocket drive hub (2)(Figure 30) from the mainshaft.

INPUT AND PLANETARY GEAR










1. Remove input gear seal with suitable screw and slide hammer.
2. Remove input gear retaining ring (2)(Figure 31) 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)(Figure 32). Tap gear out of bearing with plastic mallet, if necessary.










4. Remove snap-ring (2) that retains input gear in the low range gear (1)(Figure 33).










5. Remove retainer (2)(Figure 34).










6. Remove front thrust plate (2)(Figure 35) from the input gear (1).










7. Remove input gear (1)(Figure 36) from the low range planetary (2).










8. Remove bottom tabbed thrust washer (2) from low range planetary (1)(Figure 37).