Intermediate Gear Assembly: Disassembly

Remove and discard 10 bolts securing bottom cover, remove cover. See Fig 1 .
Remove 7 bolts securing differential lock selector side cover. See Fig 2 .
Remove side cover.
Release staking from intermediate shaft nut, remove and discard nut. See Fig 3 .
Remove bolt securing intermediate shaft retaining plate, remove plate.
Remove intermediate shaft and discard 2 "O" rings. See Fig 4 .
Remove intermediate gear assembly and collect bearings and selective spacer. See Fig 5 .
Secure gear assembly in a soft jawed vice and using a suitable drift, remove and discard bearing tracks. See Fig 6 .
On vehicles up to 2003 Model Year, remove and discard circlips.

Fig 1: Removing Transfer Box Bottom Cover

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Fig 2: Removing Transfer Box Differential Lock Selector Side Cover

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Fig 3: Removing Transfer Box Intermediate Shaft Nut

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Fig 4: Locating Transfer Box Intermediate Shaft "O" Rings

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Fig 5: Removing Transfer Box Intermediate Gear Assembly

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Fig 6: Removing Intermediate Gear Assembly Bearing Tracks

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