Disassembly

DISASSEMBLY
1. REMOVE VEHICLE SPEED SENSOR ASSEMBLY
a. Remove the bolt and vehicle speed sensor assembly.
b. Remove the O-ring from the vehicle speed sensor assembly.
c. Remove the clip and vehicle speed sensor driven gear from the vehicle speed sensor assembly.
2. REMOVE 3 PLUGS AND GASKETS FROM FRONT CASE
3. REMOVE PROTECTOR
Remove the 4 bolts and protector.

4. REMOVE FRONT BEARING RETAINER
a. Remove the 5 bolts.
b. Using a plastic hammer, tap the front bearing retainer and remove it.
5. REMOVE UPPER COVER AND OIL DEFLECTOR
Remove the 4 bolts, upper cover, 2 gaskets and oil deflector.

6. REMOVE FRONT COMPANION FLANGE
a. Using a chisel and hammer, loosen the staked part of the front companion flange lock nut.
b. Using SST, hold the front companion flange and remove the front companion flange lock nut.
SST 09330-00021

c. Using SST, remove the front companion flange.
SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04051, 09957-04010, 09958-04011)
7. REMOVE REAR COMPANION FLANGE
Remove the rear companion flange in the same way as the front companion flange.

8. REMOVE EXTENSION HOUSING
a. Remove the 5 bolts.
b. Using a plastic hammer, tap the extension housing and remove it.
9. REMOVE VEHICLE SPEED SENSOR DRIVE GEAR
a. Remove the 2 output washers and vehicle speed sensor drive gear.
b. Using a magnetic finger, remove the ball from the rear output shaft.

10. SEPARATE FRONT CASE AND REAR CASE
a. Remove the 12 bolts and 2 clamps.
b. Using a plastic hammer, tap the front case and rear case and separate them.
11. REMOVE SHIFT FORK SHAFT

a. Using a hexagon wrench (6 mm), remove the 2 straight screw plugs, springs and balls from the front drive and high and low shift forks.

b. Using 2 screwdrivers and a hammer, tap out the 2 snap rings from the shift fork shaft.

c. Remove the bolt and shift fork shaft stopper.

d. To pull out the shift fork shaft, shift the front drive and high and low shift forks to the positions as shown in the illustration.
e. Pull out the shift fork shaft.

f. Using a magnetic finger, remove the 2 straight pins from the front drive and high and low shift forks.
12. REMOVE REAR OUTPUT SHAFT ASSEMBLY, DRIVEN SPROCKET ASSEMBLY, CHAIN AND FRONT DRIVE AND HIGH AND LOW SHIFT FORKS

a. Using 2 screwdrivers and a hammer, tap out the snap ring from the shift fork shaft of the actuator assembly.

HINT: Remove only the snap ring on the front side of the shift fork shaft.

b. Using a snap ring expander, remove the snap ring.

c. Mount the rear case in a vise.
d. Using a plastic hammer, carefully tap the rear case, and remove the rear output shaft assembly, driven sprocket assembly, chain and front drive and high and low shift forks with an assembly.
e. Remove the driven sprocket assembly, chain and front drive and high and low shift forks from the rear output shaft assembly.
13. REMOVE ACTUATOR ASSEMBLY

a. Using 2 screwdrivers and a hammer, remove the snap ring.
b. Remove the 3 bolts and actuator assembly.

c. Remove the O-ring, transfer 4WD position switch and transfer L4 position switch and 2 gaskets from the actuator assembly.

14. REMOVE SEPARATOR WITH OIL STRAINER AND MAGNET
Remove the 3 bolts, separator with the oil strainer and magnet.

15. REMOVE OIL PUMP BODY ASSEMBLY
Remove the 3 bolts and oil pump body assembly.
16. REMOVE OIL PUMP DRIVE GEAR
17. REMOVE PLANETARY GEAR ASSEMBLY WITH INPUT SHAFT ASSEMBLY