Disassembly/Assembly

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 removal 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.

Fig. 35 Rear retainer:

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.

Fig. 36 Rear case:

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.

Fig. 37 Removal of sprocket & drive chain:

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

Fig. 38 Range fork & hub:

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

Fig. 39 Input gear snap ring:

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

Fig. 40 Removal of input gear bearing:

23. Remove input gear bearing, using bearing removal tools No. C-4171 and C-4210 or equivalents.
24. Remove synchronizer snap ring from mainshaft, then remove synchronizer assembly.

Fig. 41 Drive sprocket needle bearings:

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

Fig. 42 Front & rear bearing position:

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

Fig. 43 Mainshaft pilot bearing:

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

Fig. 44 Installing mainshaft pilot bearing:

28. Install mainshaft pilot bearing using tools No. C-4171 and 5065 or equivalents.

Fig. 45 Rear output seal:

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

Fig. 46 Rear output bearing:

30. Remove rear output bearing using tools No. C-4610 and C-4171 or equivalents.
31. Remove front output shaft front bearing.

Fig. 47 Front output shaft rear bearing:

32. Remove front output shaft rear bearing using tools No. 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 which show excessive wear, distortion or damage.
35. Reverse procedure to assemble. Use Permatex No. 3 sealer or equivalent on transmission to transfer case gasket.