1. Remove the manual transmission assembly from the vehicle. 
2. Remove the clutch release lever.
3. Remove the transfer case together with the extension case assembly.
4. Remove the bearing mounting bolt.
5. Remove the main shaft rear plate.
|
(A) |
Main shaft rear plate |
6. Remove the coupling bolts and nuts, and separate the transmission case into the right and left case.
7. Remove the drive pinion shaft assembly from the left side of the transmission case.
NOTE:
Use a hammer handle, etc. to remove if too tight.
|
(A) |
Main shaft ASSY for single-range |
|
(B) |
Drive pinion shaft ASSY |
8. Remove the main shaft assembly for single-range.
9. Remove the front differential assembly.
NOTE:
• Do not confuse the right and left roller bearing outer races.
• Be careful not to damage the oil seal of retainer.
1. Remove the manual transmission assembly from the vehicle.
2. Remove the clutch release lever.
3. Remove the transfer case together with the extension case assembly.
4. Remove the input shaft holder.
|
(A) |
Input shaft holder |
|
(B) |
Input shaft |
5. Remove the high-low switch.
6. Use the ST to push out the straight pin and remove the high-low shifter lever.
| ST 398791700 | STRAIGHT PIN REMOVER 2 |
NOTE:
• When pushing out the straight pin, push out in the direction away from the transmission case.
• Do not reuse the straight pin.
|
(A) |
Straight pin |
|
(B) |
High-low shifter lever |
7. Remove the main shaft rear plate.
|
(A) |
Main shaft rear plate |
8. Remove the coupling bolts and nuts, and separate the transmission case into the right and left case.
9. Using the handle portion of a hammer, etc., remove the drive pinion shaft assembly from the left side of the transmission case.
|
(A) |
Main shaft ASSY for dual-range |
|
(B) |
Drive pinion shaft ASSY |
10. Lift the main shaft assembly slightly, and remove the high-low shifter fork along with the high-low shifter shaft.
NOTE:
Be careful not to drop the 2 high-low shifter pieces.
|
(A) |
High-low shifter fork |
|
(B) |
Input shaft ASSY |
11. Remove the main shaft assembly and input shaft assembly.
NOTE:
The input shaft and main shaft will come apart, so make sure not to drop the assembly.
|
(A) |
Main shaft ASSY |
|
(B) |
Input shaft ASSY |
12. Remove the front differential assembly.
NOTE:
• Do not confuse the right and left roller bearing outer races.
• Be careful not to damage the oil seal of retainer.