Disassembly

Remove Chain Cover:

Remove Chain Oiler:

Remove Chain Snubber:

Remove Output Shaft Sprocket Snap Ring And Wave Washer:

Remove Transfer Shaft Sprocket Snap Ring And Wave Washer:

CAUTION: The chain sprockets have a slip fit onto their shafts. Apply only a slight amount of pressure to the chain spreader to release the chain pressure. If chain sprockets are not spread slightly removal or installation will be difficult. Overspreading of the chain sprocket will also make sprocket removal difficult.

CAUTION: To ensure proper gear ratio, verify that the correct chain and sprocket ratio is selected.

Install Chain Spreader:

Remove Chains And Sprockets As An Assembly:

CAUTION: When reinstalling drive chains, the blue link must face outward.

Remove Long Stub Shaft Snap Ring:

Remove Long Stub Shaft:

CAUTION: Driveshaft retainer clips and seals located on the stub shafts must be replaced before reinstalling driveshafts.

Remove Inner Differential Adjuster Lock:

Remove Outer Adjuster:

Loosen Outer Adjuster:

Remove Side Cover, Carrier And Ring Gear Assembly:

If the carrier requires reconditioning, refer to Differential Carrier Recondition.

Remove Inner Adjuster By Turning Clockwise:

Remove Differential Vent Baffle:

CAUTION: Failure to grind and open stakes on the transfer shaft nut will result in thread damage to transfer shaft during nut removal.

WARNING: Wear safety goggles while grinding stake nuts.

Grinding Stakes:

Stake Grinding Pattern:

Using a die grinder or equivalent, grind the stakes in the shoulder of the shaft nut as shown. Do not grind through the transfer shaft nut into the shaft. There are two stakes on the nut.

Opening Nut Stakes:

Using a small chisel, carefully open stakes on nut.

Press Transfer Shaft Downward To Remove Rear Cone:

Remove the transfer shaft nut.

CAUTION: Do not reuse old transfer shaft nut because the removed stake weakens the nut flange.

CAUTION: The transfer shaft cannot be removed from the case at this time.

Transfer Bearing Cup Removal:

Install special tool 6577, or equivalent to remove rear transfer bearing cup.

Preload Shim Removal:

Remove transfer shaft preload shim. If transfer shaft bearings are to be reused, the original shim must also be reused.

Remove Transfer Shaft Assembly From Case:

CAUTION: If the transfer shaft is removed from the transaxle case for any reason, both seals must be replaced.

Transfer Shaft Seal Remover:

Remove transfer shaft seals using special tool 6310 and foot 6310-9 (Tar 960), or equivalent. Do not reuse old seals. The seals will be pulled out the rear of the case.

Front Transfer Shaft Cup Removal:

Remove the front transfer shaft bearing cup using special tool 6495 and handle C-4171, or equivalents. Use a press with special tools to remove cup.

Remove Front Transfer Shaft Bearing And Pinion Depth Shim:

Support special tool P-334, or equivalent on press table so that pinion head of transfer shaft can be pressed through table.