1. Remove the manual transmission assembly from the vehicle. 
2. Remove the clutch release lever.
3. Remove the transfer case together with the extension case assembly.
4. Remove the bearing mounting bolt.
5. Remove the main shaft rear plate.
|
(A) |
Main shaft rear plate |
6. Separate the transmission case into the right and left cases by loosening the coupling bolts and nuts.
7. Remove the drive pinion shaft assembly from the left side of the transmission case.
NOTE:
Use a hammer handle, etc. to remove if too tight.
|
(A) |
Main shaft ASSY for single-range |
|
(B) |
Drive pinion shaft ASSY |
8. Remove the main shaft assembly for single-range.
9. Remove the front differential assembly.
NOTE:
• Do not confuse the right and left roller bearing outer races.
• Be careful not to damage the oil seal of retainer.
1. Remove the manual transmission assembly from the vehicle.
2. Remove the clutch release lever.
3. Remove the transfer case together with the extension case assembly.
4. Remove the input shaft holder.
|
(A) |
Input shaft holder |
|
(B) |
Input shaft |
5. Remove the high-low switch.
6. Use the ST to push out the straight pin and remove the high-low shifter lever.
| ST 398791700 | STRAIGHT PIN REMOVER 2 |
NOTE:
When pushing out the straight pin, push out in the direction away from the transmission case.
|
(A) |
Straight pin |
|
(B) |
High-low shifter lever |
7. Remove the main shaft rear plate.
|
(A) |
Main shaft rear plate |
8. Separate the transmission case into the right and left cases by loosening the coupling bolts and nuts.
9. Remove the drive pinion shaft assembly from the left side of the transmission case using the handle part of a hammer, etc.
NOTE:
Use a hammer handle, etc. to remove if too tight.
|
(A) |
Main shaft ASSY for duel-range |
|
(B) |
Drive pinion shaft ASSY |
10. Slightly lift the main shaft assembly, and remove the high-low shifter shaft and washer along with the high-low shifter fork.
NOTE:
Be careful not to drop the 2 high-low shifter pieces.
|
(A) |
High-low shifter fork |
|
(B) |
Input shaft ASSY |
11. Remove the main shaft assembly and input shaft assembly.
NOTE:
The input shaft and main shaft will come apart, so make sure not to drop the assembly.
|
(A) |
Main shaft ASSY |
|
(B) |
Input shaft ASSY |
12. Remove the front differential assembly.
NOTE:
• Do not confuse the right and left roller bearing outer races.
• Be careful not to damage the oil seal of retainer.