Dual Range 4WD Models
- Set transmission in stand. Remove clutch release fork and release bearing holder complete. Remove transfer case cover. Punch out the spring pin connecting high-low shifter rod to rod arm. Remove clip on transfer shifter rail with screwdriver after shifting transfer shifter rail into "4WD LO" position.
- Pull out transfer shifter rail after shifting into "4WD HI" position. When pulling out, fix both high-low shifter arm and transfer shifter fork into "4WD HI" position in order not to interlock plunger. Be careful that ball does not fly out and drop into transfer case. Remove pin and clip on interlock rail with pliers.
- Pull out interlock rail by turning 90°. Be careful that pin and clip on interlock rail do not fly out. Remove transfer shifter fork from transfer case, turning it in order not to interfere with high-low shifter rail. Be careful not to loose ball and spring. Remove extension assembly.
- Loosen front nut of rod adjusting screw connecting high-low shifter rod with ball joint assembly, and loosen rear nut (nut is left-hand threaded). Disconnect high-low shifter rod from rod arm by turning rod adjust arm screw clockwise. Disconnect rod ball joint assembly from high-low shifter center pivot by removing nut.
- Punch out spring pin connecting high-low shifter rail to rod arm and remove rod arm. Punch out spring pin connecting high-low shifter rail to high-low shifter arm and remove high-low shifter rail and arm. Be careful not to lose ball and plunger. Lock transmission main shaft with stopper (498787000). Release staking and remove lock nut.
- Shift gear to 1st position to prevent shaft from turning. Remove transfer case attaching bolts. Pull out transfer case by about .040" (10 mm). Separate transfer case from main case by tapping with plastic hammer. Remove ball bearing attaching bolts at the drive pinion gear.
- Remove input shaft holder attaching bolts. Wrap spline portions of axle shafts with vinyl tape. Separate transmission main case into left and right halves. Remove clutch cable bracket, oxygen sensor harness clip, radio ground, back-up light clips, clutch cable clamp, and stopper plate.
- Punch out spring pin and remove high-low shift lever center pivot. Turn 90° and remove high-low shift fork. Pull countergear shaft forward until it hits on transmission main case and remove clip with screwdriver. Slide countergear washer to the rear and remove knock pin from countergear shaft.
- Remove countergear shaft from main case being careful not to drop countergear and washers. Remove countergear from main case. Remove drive pinion as shown in Figure . Remove transmission main shaft. Remove differential. See Figure . DO NOT mix right and left roller bearing outer races.
- Remove plugs, gaskets, springs and balls from case. Unscrew shifter fork set screws, and remove 3rd-4th and 1st-2nd shifter forks as well as shifter rails. Remove shifter set screw, reverse shifter rail arm and reverse shifter rail.
- Remove oil seal holder lock plates, axle shaft oil seal holders and "O" rings. Remove snap ring and speedometer driven gear. Remove knock pins, reverse idler gear shaft, reverse idler gear and shifter lever.
- Remove 3 shift rail plugs, springs and balls. Unscrew shift fork set screws and remove shift forks and fork rails. When pulling out a rail, keep other rails in neutral position. To remove 3rd-4th rail, rotate it 90°. Take care not to drop shifter rail plungers.
- Remove reverse shift fork set screw and remove reverse shift rail arm and reverse shift rail. Remove transaxle case bolts and remove output shaft oil seal holder lock plates. Using remover (399780111), remove drive axle shaft oil seal holder and "O" ring.
- Remove speedometer driven gear snap ring and gear. Lightly tap speedometer shaft out of case. Oil seal should come out with shaft. Remove reverse idler gear shaft retaining pins. Remove reverse idler gear shaft, idler gear and shift lever.
NOTE:
When removing reverse shift rail arm, ensure ball does not pop out of case.