Transfer Case: Disassembly
- Use snap-ring pliers to remove snap ring from output shaft. Remove output mainshaft end ball bearing using Bearing Remover (J-8614-11). Temporarily install front companion flange. Use Companion Flange Holder (J-37221) to prevent shaft from rotating. Remove lock nut with Lock Nut Wrench (J-32719). Remove companion flange.
- Remove input shaft snap ring. Remove input shaft assembly from transfer case. Using puller, remove high-low clutch hub and sleeve. Remove transfer input gear. Remove needle bearing cage and remove bearing collar, ball and plate. See Fig 1.
Courtesy of ISUZU MOTOR CO.
- Remove ball bearing from input shaft, using press. Remove input shaft and bearing snap ring. Remove front output gear assembly from case by tapping out with plastic mallet. Remove bearing snap ring, bearing and collar. On M/T models, using press, remove sub-gear snap ring, spacer, Belleville spring and sub-gear. On all models, remove needle bearing with press. Remove inside ring, outside ring and block ring.
- Disassemble 2WD-4WD clutch spring, inserts, clutch hub and sleeve. Remove and discard stopper plate. Using press, remove ball bearing. Remove front output shaft. Remove bearing snap ring. Remove counter gear assembly from transfer case. Remove snap ring.
- Using press, remove ball bearing. Remove snap ring and next ball bearing. Remove spacer, Belleville spring, sub-gear (anti-lash plate) and counter gear.