Transfer Assembly: Disassembly

1. Remove the 9 bolts.
   Fig 1: Locating Transfer Oil Pan Bolts

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2. Insert the blade of SST between the transfer oil pan and transfer case. Cut through the sealer and remove the transfer oil pan.

   SST 09032-00100 

   NOTE: Do not damage the contact surface of the transfer oil pan.
   Fig 2: Inserting Blade Of SST Between Transfer Oil Pan And Transfer Case

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3. Remove the transfer oil cleaner magnet from the transfer oil pan.
   NOTE:

   • Clean the inside of the oil pan thoroughly, removing all metal shavings, sludge and any other foreign objects.
   • Remove any metal shavings from the magnet.
   Fig 3: Removing Metal Shavings From Magnet

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1. Remove the 4 bolts and the transfer valve body assembly.
2. Disconnect the transfer wire connector from the transfer control solenoid.
   Fig 4: Locating Transfer Wire Connector & Valve Body Bolts

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3. Remove the bolt and the transfer wire.

Fig 5: Locating Transfer Wire Removing Bolt

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1. Using SST, remove the transfer extension housing dust deflector.

SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04051, 09958-04011) 

Fig 6: Removing Transfer Extension Housing Dust Deflector Using SST

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1. Remove the 8 bolts and clamp.
   Fig 7: Locating Transfer Case Bolts

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2. Using a plastic hammer, tap the transfer case to remove it.

Fig 8: Taping Transfer Case

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1. Remove the transfer rear output shaft assembly.

Fig 9: Removing Transfer Rear Output Shaft Assembly

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1. Using SST and a hammer, release the staked part of the nut.

   SST 09930-00010 

   NOTE:

   • Be sure to use the SST with the tapered surface facing the shaft.
   • Do not grind the tip of the SST with a grinder etc.
     Fig 10: Releasing Flange Yoke Nut Using SST & Hammer

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   • Completely loosen the staked part of the nut when removing it.
   • Do not damage the threads of the transfer drive sprocket.
2. Using SST, hold the yoke.

   SST 09330-00021, 09213-54015 

3. Using a deep socket wrench (30 mm), remove the nut.
4. Remove the flange yoke.

Fig 11: Removing Flange Nut

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1. Remove the 10 bolts.
   Fig 12: Locating Rear Transfer Chain Case Bolts

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2. Tap the 3 protrusions of the transfer chain case gently with a brass bar and hammer to loosen, and remove it.

Fig 13: Locating Protrusions Of Transfer Chain

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1. Remove the transfer front drive chain, transfer drive sprocket and transfer front driven clutch sleeve.
2. Remove the transfer front drive chain from the transfer drive sprocket and transfer front driven clutch sleeve.

Fig 14: Removing Transfer Front Drive Chain

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1. Remove the 6 bolts and front transfer chain case.

HINT:

If necessary, tap the transfer chain case front with a plastic hammer to loosen and remove it.

Fig 15: Identifying Front Transfer Chain Case Removing Bolts

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1. Using a screwdriver with its tip taped, pry out the oil seal from the transfer case.
   Fig 16: Removing Transfer Case Rear Oil Seal

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2. Remove the bolt and clamp.

Fig 17: Removing Bolt & Clamp

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1. Using SST, remove the transfer case bearing from the transfer case.

SST 09308-00010 

Fig 18: Removing Transfer Case Bearing Using SST

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1. Remove the bolt and transfer baffle valve from the rear transfer chain case.

Fig 19: Removing Transfer Baffle Valve Sub-Assembly

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1. Remove the screw, O-ring, and 2 gaskets from the front transfer chain case.
   Fig 20: Removing Screw, O-Ring & Gaskets From Transfer Chain Case

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2. Remove the 2 gaskets from the rear transfer chain case.

Fig 21: Removing Gaskets From Rear Transfer Chain Case

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1. Using a screwdriver with its tip taped, pry out the oil seal from the transfer chain case front.

Fig 22: Removing Transfer Case Front Oil Seal

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1. Remove the center differential carrier from the transfer rear output shaft and transfer direct clutch drum.

Fig 23: Identifying Center Differential Carrier

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1. Remove the transfer rear output shaft bearing from the transfer direct clutch drum.

Fig 24: Identifying Transfer Rear Output Shaft Bearing

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1. Using a screwdriver with its tip taped, remove the snap ring from the transfer direct clutch drum.
   Fig 25: Removing Snap Ring From Transfer Direct Clutch Drum

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2. Remove the 2 center differential clutch disc flanges and center differential clutch disc set from the transfer direct clutch drum.

   HINT:

   • A: Center differential clutch disc flange (No. 1)
   • B: Center differential clutch disc set (Discs)
   • C: Center differential clutch disc set (Plates)
   • D: Center differential clutch disc flange (No. 2)

Fig 26: Removing Center Differential Clutch Disc Set & Flanges

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1. Place SST on the center differential clutch pressure balancer, and compress the return spring with a press.
   Fig 27: Removing Snap Ring Using SST

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   SST 09350-30020 (09350-07040) 

2. Using SST, remove the snap ring.

   SST 09350-30020 (09350-07040, 09350-07070) 

3. Remove the center differential clutch pressure balancer from the transfer direct clutch drum.

Fig 28: Identifying Center Differential Clutch Pressure Balancer

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1. Remove the transfer direct clutch return spring from the transfer direct clutch drum.

1. Install the transfer direct clutch drum to the transfer center support.
   Fig 30: Installing Transfer Direct Clutch Drum To Transfer Center Support

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2. While pushing down evenly on the center differential clutch piston, apply air (200 kpa, 2.0 kgf*cm2, 19 psi) into the oil hole on the transfer chain case rear as shown in Fig 31 to remove the center differential clutch piston from the transfer direct clutch drum.
   Fig 31: Removing Center Differential Clutch Piston From Transfer Direct Clutch Drum

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3. Remove the direct clutch drum from the transfer center support.

1. Remove the 2 O-rings from the center differential clutch piston.
   Fig 32: Locating O-Rings On Center Differential Clutch Piston

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1. Remove the 5 bolts and transfer center support.
2. Remove the 2 screws and 2 O-rings from the rear transfer chain case.

Fig 33: Removing Transfer Center Support

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1. Remove the 2 transfer center support seal rings from the transfer center support.

1. Using SST and a press, remove the transfer driven sprocket bearing from the transfer front driven clutch sleeve.

   SST 09950-00020 

   Fig 35: Removing Transfer Driven Sprocket Bearing From Transfer Front Driven Clutch Sleeve Using SST

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2. Using SST and a press, remove the transfer driven sprocket bearing from the transfer front driven clutch sleeve.

SST 09950-60010 (09951-00530), 09950-70010 (09951-07100) 

Fig 36: Removing Transfer Driven Sprocket Bearing From Transfer Front Driven Clutch Sleeve Using SST

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1. Using SST and a press, remove the transfer drive sprocket bearing from the transfer drive sprocket.

   SST 09950-00020, 09950-70010 (09951-07100), 09950-60010 (09951-00480) 

   Fig 37: Removing Transfer Drive Sprocket Bearing From Transfer Drive Sprocket Using SST

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2. Using SST and a press, remove the transfer drive sprocket bearing from the transfer drive sprocket.

SST 09950-00020, 09950-70010 (09951-07100), 09950-60010 (09951-00550) 

Fig 38: Removing Transfer Drive Sprocket Bearing From Transfer Drive Sprocket Using SST

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1. Remove the bolt, solenoid lock plate and transfer control solenoid.

Fig 39: Identifying Bolt For Removing Transfer Control Solenoid

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1. Remove the 6 bolts.
   Fig 40: Locating Transfer Valve Body Cover Bolts

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2. Remove the transfer valve body cover and upper transfer valve body plate from the transfer upper valve body.
3. Remove the solenoid oil strainer from the transfer valve body cover.

Fig 41: Removing Transfer Valve Body Cover & Upper Transfer Valve Body Plate

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1. While pushing on the transfer modulator valve plug, remove the transfer solenoid modulator valve plug seat from the transfer upper valve body.
   Fig 42: Removing Transfer Solenoid Modulator Valve Plug Seat

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2. Remove the transfer solenoid modulator valve plug, transfer solenoid modulator valve and low-high shift valve compression spring from the transfer upper valve body.

Fig 43: Removing Transfer Solenoid Modulator Valve Plug, Transfer Solenoid Modulator Valve & Low-High Shift Valve Compression Spring

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1. While pushing on the center differential clutch control valve plug, remove the center differential clutch control valve plug seat from the transfer upper valve body.
   Fig 44: Removing Center Differential Clutch Control Valve

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2. Remove the center differential clutch control valve plug, center differential clutch control valve, transfer direct clutch modulator valve spring and center differential clutch control valve sleeve from the transfer upper valve body.

Fig 45: Removing Center Differential Clutch Control Valve Sleeve

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