Chain, Sprocket and Mechanical Lock (Transfer Case Assembly)

Chain, Sprocket and Mechanical Lock (Transfer Case Assembly)









Disassembly
1. Remove the spacer.





2. Remove the front tone wheel, lower drive sprocket, drive sprocket and chain together from the front and rear output shaft.





3. Remove the lockup collar assembly and lockup fork together.
4. Remove the lockup hub.
5. Remove the thrust washer.





6. Remove the magnet from the strainer set position together with the oil pump assembly.
7. Remove the output shaft.





8. Remove the cam and shaft rail assembly.
9. Remove the shift fork and rail assembly, and reduction hub.
10. Remove the spring pin from the shift fork and rail assembly.
11. Remove the shift fork assembly from the lockup rail.
12. Remove the front output shaft from the transfer case.

Reassembly
1. Apply ATF to the inside of the ball bearing.





2. Install the front output shaft to the transfer case.
3. Install the shift fork assembly to the lockup rail and fix the assembly with the snap ring.





4. Install the shaft fork and rail assembly and reduction hub to the transfer case.
5. Install the output shaft to the transfer case.
6. Install the oil pump assembly to the output shaft and attach the magnet to the strainer set position.
7. Install the thrust washer.
8. Install the lockup hub.





9. Install the cam and shaft rail assembly.





10. Install the lockup collar assembly and lockup fork together.
11. Apply ATF to the chain and engage it to both sprockets.
12. Mount the chain and sprocket assembly to both output shafts.

Note: When installing chain, the copper colored ring of the chain (indicated by the arrow) to be installed in direction of rear.

13. Install the front torn wheel to the front output shaft.





14. Install the spacer to the drive sprocket assembly.