Transfer Gears - Disassemble
Disassembly Procedure
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| Required Tools | |||
| Tool | Part Number | Part Description | Qty |
| A | 138-7575 | Link Bracket | 2 |
| B | 1U-7600 | Slide Hammer Puller | 1 |
| C | 1P-7409 | Eyebolt | 1 |
| D | 8B-7551 | Bearing Puller | 1 |
| E | 8B-7548 | Push-Puller Tool Group | 1 |
| F | 1P-0520 | Driver Group | 1 |
Start By:
- Remove the transmission and transfer gears. Refer to Disassembly and Assembly, "Transmission and Transfer Gears - Remove".
- Disassemble the transmission. Refer to Disassembly and Assembly, "Transmission Planetary - Disassemble".
- Remove dust cap (1) from transfer case (2) .
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| Illustration 1 | g00512385 |
- Remove bolts (3) from transfer case (2) .
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| Illustration 2 | g00512406 |
- Use Tooling (A) and a suitable lifting device to remove bearing cage (4) from transfer case (2). The weight of bearing cage (4) is approximately 25 kg (55 lb).
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| Illustration 3 | g01014384 |
- Remove shim pack (5) from transfer case (2) .
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| Illustration 4 | g00512412 |
- Remove O-ring seals (6) and (7). Remove ball (8) from bearing cage (4) .
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| Illustration 5 | g00512414 |
- Drill three small holes in lip seal (9). Use Tooling (B) to remove lip seal (9) from bearing cage (4) .
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| Illustration 6 | g00512416 |
- Remove bearing cup (10) from bearing cage (4) .
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| Illustration 7 | g00512418 |
- Use Tooling (C) and a suitable lifting device to remove transfer gear (11) from transfer case (2). The weight of transfer gear (11) is approximately 66 kg (145 lb).
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| Illustration 8 | g00512420 |
- Use Tooling (D) and Tooling (E) to remove bearing cone (12) from transfer gear (11) .
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| Illustration 9 | g00512422 |
- Turn over transfer gear (11). Use Tooling (D) and Tooling (E) to remove bearing cone (13) from transfer gear (11) .
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| Illustration 10 | g00512425 |
- Remove tube assembly (14) and the flared elbow. Remove bearing cup (15), orifice plug (16), and ball (17) from transfer case (2) .
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| Illustration 11 | g00512427 |
- Remove tube (18) and flared connector (19) from transfer case (2) .
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| Illustration 12 | g00512428 |
- Remove nipple (20) and the O-ring seal. Remove ball (21) from transfer case (2) .
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| Illustration 13 | g00512430 |
- Remove plug (22) and the O-ring seal. Remove adapter (23) and the O-ring seal from transfer case (2) .
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| Illustration 14 | g00512432 |
- Remove bolts (24). Remove brass washer (25) from transfer case (2) .
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| Illustration 15 | g00512434 |
- Use Tooling (A) and a suitable lifting device to remove bearing cage (26) from transfer case (2). The weight of bearing cage (26) is approximately 34 kg (74 lb).
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| Illustration 16 | g01014379 |
- Remove shim pack (27) from transfer case (2) .
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| Illustration 17 | g00512438 |
- Remove bolts (28) and seal rings (29) from carrier (30) .
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| Illustration 18 | g00512439 |
- Use Tooling (F) (not shown) and a suitable press to remove carrier (30) and roller bearing cup (31) from bearing cage (26) .
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| Illustration 19 | g00512440 |
- Remove orifice plug (32) from carrier (30) .
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| Illustration 20 | g00512442 |
- Use Tooling (D) and (E) in order to remove race (33) from carrier (30) .
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| Illustration 21 | g00512443 |
- Remove plug (34) and the O-ring from bearing cage (26) .
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| Illustration 22 | g00512444 |
- Use a suitable lifting device to remove transfer gear (35) from transfer case (2). The weight of transfer gear (35) is approximately 41 kg (90 lb).
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| Illustration 23 | g00512446 |
- Remove roller bearing cone (36) from transfer gear (35) .
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| Illustration 24 | g00512448 |
- Turn over transfer gear (35). Remove roller bearing cone (37) from transfer gear (35) .
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| Illustration 25 | g00512450 |
- Remove roller bearing cup (38) from transfer case (2) .
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| Illustration 26 | g00512452 |
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