Transfer Assembly: Disassembly

1. Remove the bolt and speedometer driven gear hole cover.
2. Remove the O-ring from the speedometer driven gear hole cover.

Remove the 4 bolts and protector.

1. Remove the 5 bolts.
2. Using a plastic hammer, tap on the front bearing retainer and remove it.
   Fig 1: Removing Front Bearing Retainer Bolts

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Remove the 4 bolts, upper cover and oil deflector.

1. Using a chisel and hammer, loosen the staked part of the front companion flange lock nut.
2. Using SST, hold the front companion flange and remove the front companion flange lock nut.

   SST 09330-00021

   Fig 2: Removing Front Companion Flange Lock Nut Using SST 09330-00021

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3. Using SST, remove the front companion flange.

   SST 09950-40011 (09951-04020,09952-04010, 09953-04030, 09954-04010, 09955-04051, 09957-04010,09958-04011)

   Fig 3: Removing Front Companion Flange Using SST

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Remove the rear companion flange in the same way as the front companion flange.

1. Remove the 5 bolts.
2. Using a plastic hammer, tap on the extension housing and remove it.
   Fig 4: Removing Extension Housing

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1. Remove the 2 output washers and vehicle speed sensor drive gear.
2. Using a magnetic finger, remove the ball from the rear output shaft.

1. Remove the 12 bolts and 2 clamps.
2. Using a plastic hammer, tap on the front case and rear case, and separate them.

Fig 5: Identifying 2 Clamps

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1. Using a hexagon wrench (6 mm), remove the 2 straight screw plugs, springs and balls from the front drive and high and low shift forks.
   Fig 6: Removing Shift Fork Shaft

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2. Using 2 screwdrivers and a hammer, tap out the 2 snap rings from the shift fork shaft.
   Fig 7: Taping Out Snap Rings From Shift Fork Shaft

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3. Remove the bolt and shift fork shaft stopper.
   Fig 8: Removing Shift Fork Shaft Stopper

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4. To pull out the shift fork shaft, shift the front drive and high and low shift forks to the positions as shown in the illustration.
5. Pull out the shift fork shaft.
   Fig 9: Identifying Shift Fork Positions For Pulling Out Shift Fork Shaft

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6. Using a magnetic finger, remove the 2 straight pins from the front drive and high and low shift forks.

Fig 10: Removing 2 Straight Pins

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1. Using 2 screwdrivers and a hammer, tap out the snap ring from the shift fork shaft of the actuator assembly.

   HINT:

   Remove only the snap ring on the front side of the shift fork shaft.

   Fig 11: Taping Out Snap Ring From Shift Fork Shaft Of Actuator Assembly

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2. Using a snap ring expander, remove the snap ring.
   Fig 12: Removing Snap Ring Using Snap Ring Expander

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3. Mount the rear case in a vise.
4. Using a plastic hammer, carefully tap the rear case, and remove the rear output shaft assembly, driven sprocket assembly, chain and front drive and high and low shift forks as an assembly.
5. Remove the driven sprocket assembly, chain and front drive and high and low shift forks from the rear output shaft assembly.

Fig 13: Removing Rear Output Shaft Assembly

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1. Using 2 screwdrivers and a hammer, remove the snap ring.
2. Remove the 3 bolts and actuator assembly.
   Fig 14: Removing Snap Ring Using 2 Screwdrivers And Hammer

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3. Remove the O-ring, transfer 4WD position switch, transfer L4 position switch and 2 gaskets from the actuator assembly.

Fig 15: Removing O-Ring, Transfer 4WD Position Switch And Transfer L4 Position Switch

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Remove the 3 bolts and separator with the oil strainer and magnet.

Fig 16: Removing Separator With Oil Strainer And Magnet

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Remove the 3 bolts and oil pump body assembly.

Fig 17: Removing Oil Pump Body Assembly

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1. Using a snap ring expander, remove the snap ring.
   Fig 18: Removing Snap Ring Using Snap Ring Expander

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2. Pull out the planetary gear assembly with the input shaft assembly.

Fig 19: Pulling Out Planetary Gear Assembly

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1. Using a screwdriver, remove the snap ring.
   Fig 20: Removing Snap Ring Using Screwdriver

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2. Remove the low gear spline piece.

Fig 21: Removing Low Gear Spline Piece

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1. Using a snap ring expander, remove the snap ring.
   Fig 23: Removing Snap Ring Using Snap Ring Expander

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2. Remove the input gear stopper, ball and thrust washer.

Fig 24: Removing Input Gear Stopper, Ball And Thrust Washer

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1. Using a screwdriver, remove the snap ring.
   Fig 26: Removing Snap Ring

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2. Remove the head screw plug, spring and pin.
   Fig 27: Removing Head Screw Plug, Spring And Pin

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3. Remove the planetary ring gear.

Fig 28: Removing Planetary Ring Gear

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Measure the resistance between the terminals as shown.

Standard: 

If the result is not as specified, replace the switch.

Fig 29: Measuring Resistance Between Switch Terminals

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