Part 2

DISASSEMBLY (Continued)

22. Remove the shift fork (1) and synchronizer sleeve (2).




SYNCHRONIZER HUB SNAP RING





23. Remove the synchronizer hub snap ring (1).




SYNCHRONIZER HUB





24. Remove the synchronizer hub (1).




HUB DRIVE AND CLUTCH GEAR ASSEMBLY





25. Remove the hub drive and clutch gear (1).










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










27. Remove the front drive sprocket (1), mainshaft drive sprocket (2), and drive chain (3) as one.










28. Remove the screws (2) holding the both chain guide rails (1) to the front housing.










29. Remove both drive chain guides (1) from the transfer case.




MAIN SHAFT





30. Remove the mainshaft (1).




SHIFT RAIL AND RANGE SLEEVE





31. Remove the shift rail (1) and range sleeve (2).




SHIFT RAIL SPRING AND SEAT





32. Remove the shift rail spring (1) and seat (2).










33. Remove the retaining snap ring (2) from the front output shaft (1).










34. Remove the front output shaft (2) from the front housing (1) and the front output shaft front bearing.




INPUT GEAR SNAP RING





35. Remove the input shaft seal with a suitable pry tool or a screw mounted in a slide hammer.
36. Remove the retaining ring (2) holding the input gear (1) assembly into the front housing.










37. Remove the input planetary gear assembly (1) from the front housing.










38. Remove the snap-ring (1) holding the input gear into the planetary gear.










39. Remove the input gear lock plate (3) from the planetary gear (2).










40. Remove the input gear (1) from the planetary gear (2).










41. Remove the rear tabbed thrust washer (1) from the planetary gear (2).