1. Remove the manual transmission assembly from the vehicle. 
2. Remove the back-up light switch and the neutral position switch.
3. Remove the transfer case together with the extension case assembly.
4. Remove the extension case assembly.
5. Pull out the straight pin.
|
(A) |
Selector lever COMPL |
|
(B) |
Straight pin |
6. Use the ST to remove the spring pin, and remove the selector lever COMPL.
| ST 398791700 | SPRING PIN REMOVER 2 |
|
(A) |
Selector lever COMPL |
|
(B) |
Selector arm No. 2 |
|
(C) |
Spring pin |
7. Pull out the selector arm No. 2 from neutral set spring.
|
(A) |
Selector arm No. 2 |
|
(B) |
Neutral set spring |
8. Remove the shifter arm collar and neutral set spring from transfer case.
|
(A) |
Shifter arm collar |
|
(B) |
Neutral set spring |
9. Remove the shifter arm No. 2, washers and thrust bearing from transfer case.
|
(A) |
Shifter arm No. 2 |
|
(B) |
Washer |
|
(C) |
Thrust bearing |
10. Use the ST to remove the spring pin, and remove the shifter arm and selector arm.
| ST 398791700 | SPRING PIN REMOVER 2 |
|
(A) |
Shifter arm |
|
(B) |
Selector arm |
|
(C) |
Spring pin |
11. Remove the oil seal from the transfer case by using a screwdriver wrapped with vinyl tape etc.
NOTE:
The illustration shows the oil seal of selector lever COMPL. Perform the same procedures for removing the shifter arm No. 2.
|
(A) |
Oil seal |
12. Remove the needle bearing from the transfer case by using a tube with the diameter of 20 mm (0.79 in) or 21 mm (0.83 in) and the ST.
| ST 18763AA000 | COMPRESSOR SHAFT |
13. Set ST1, ST2 and transfer case to a press.
NOTE:
• Set the ST2 under ST1.
• Set the transfer case so that the hole for shifter arm is positioned vertically.
| ST1 498267300 | CYLINDER HEAD TABLE |
| ST2 498267200 | CYLINDER HEAD TABLE |
14. Remove the roller bearing by using a round bar with the diameter of 22 mm (0.87 in) or 23 mm (0.91 in).
15. Flip over the transfer case, and set an iron plate between transfer case and ST.
NOTE:
• Insert the iron plate which is thicker than the exposed length of the transfer case knock pin between the ST and transfer case.
• Set the iron plate so that the transfer case knock pin does not ride on the iron plate.
16. Remove the roller bearing by using a tube with the diameter of 22 mm (0.87 in) or 23 mm (0.91 in).
|
(A) |
Iron plate |
17. Remove the plunger and check ball spring from transmission cover.
|
(A) |
Plunger |
|
(B) |
Checking ball spring |
|
(C) |
Transmission cover |
|
(D) |
Seal ring |
|
(E) |
Seal bolt |