Transfer case disassembly

Note. When removing the components of the transfer case, mark for yourself their installation position - this will greatly facilitate subsequent assembly.

1. Give a fixing bolt and remove assembly of a drive of a speedometer.

2. Give the fixing bolts and, using a pair of levers, remove the rear crankcase from the transfer case (the appearance of the box with the rear crankcase removed is shown in the accompanying illustration). Be careful not to damage the mating surfaces of the components.





3. Attach the dial gauge to the transfer case by pushing its plunger against the front drive sprocket (see accompanying illustration) and move the star back and forth. Read the instrument indicator reading. If the axial play is out of range (see tables of sizes and adjustments at the end of the guide), disassemble the driven shaft and carefully examine the condition of the sprocket and related components. Replace worn and defective parts.


4. Remove the oil drain and remove the speedometer drive gear from the driven shaft.

5. Remove the retaining ring from the 2-4 shift fork on your stem (components of the transfer case shift mechanism are shown in the accompanying illustration).



6. Give fixing bolts and by means of couple of levers remove the central case of a distributing box with assembly of a conducted shaft from a forward case. Be careful not to damage mating surfaces. Remove the shim from the intermediate shaft rear bearing.

7. Remove the retaining ring and remove the sleeve and spring from the shift rod 2-4. Try to remember the installation position of the sleeve. Discard the retaining ring.

8. Using a blade-type feeler gauge, measure the clearance between the underdrive gear and the overdrive/underdrive hub (see accompanying illustration). If the underdrive gear backlash is out of range, carefully check the condition of the components. Replace worn and damaged parts.




9. Remove the circlip from the forward end of the output shaft.

10. Install the bearing cage between the up/down hub and the underdrive gear, slide the puller jaws under the cage and remove the hub (see accompanying illustration). Remove the underdrive gear and roller bearing from the driven shaft. Using the T45 head, loosen the bearing holder screws, alternately knock out the driven and front output shafts so that they can be removed from the central crankcase. Remove the drive chain from the driven and front output shafts.

Input and driven shaft assembly removed from transfer case

11. Remove the 4WD signal sensor switch from the front crankcase and, on models with АТ, the start enable sensor switch (components of the front case of the transfer case are shown in the accompanying illustration).

12. Remove the plugs and remove the springs and retainer balls from the front crankcase.

13. Remove shift rods, up/down shift clutch and shift fork. Remove the roller bearing from the input shaft. Remove the detent plunger from the detent spring hole.



14. Give bolts and by means of the lever remove the holder of the input shaft bearing from a forward crankcase.

15. Try not to damage the mating surfaces.

16. Use a soft-faced hammer to knock out the intermediate and input shafts from the front crankcase.

17. Loosen the pin nut and tap the end of the nut with a soft-faced hammer until the pin is partially out of the control lever. Remove the nut and remove the pin.

18. Remove the control lever from the internal shift lever, remove the shift lever from the front crankcase and use a screwdriver to remove the oil seal. Discard the seal.


19. Remove the circlip and spacer, then use a puller and a suitable steel plate to remove the bearing from the input shaft.

Input shaft components

20. Using a puller, remove the bearings from the front output shaft (shaft components are shown in the accompanying illustration):



21. Disassemble the driven shaft (see accompanying illustration):

• Install the driven shaft in the press, supporting the drive sprocket with the plates of the latter. Remove the rear bearing, clutch gear, drive sprocket and synchronizer assembly from the shaft.
• Remove the synchronizer blocking ring, then slowly remove the synchronizer sleeve from the drive sprocket, noting the installation position of the sliding keys. Make sure that the keys with the spring do not pop out during the process of removing the clutch.
• Remove the bearing retainer, drive sprocket and roller bearing.
• Remove the snap ring and distance ring from the driven shaft. Install the shaft in the press, supporting the plates of the last front bearing and remove the bearing from the shaft.

22. Disassemble the intermediate shaft into components (see accompanying illustration):

• Remove the circlip and distance ring from the front end of the intermediate shaft.
• Using a press, remove the front and rear bearings, then remove the spacers, belleville springs, and toothed rings.

23. Remove the input shaft, then use a puller or sliding-face hammer to remove the drive flange seals.