Table of Contents
Advertisement
•
TRANSFER CASE
21 - 135
TRANSFER CASE DISASSEMBLY
REAR RETAINER
AND OUTPUT
SHAFT
REMOVAL/DISASSEMBLY
(1) Loosen rear yoke n u t u n t i l only 2-3 threads are
h o l d i n g n u t on shaft.
(2) Remove bolts a t t a c h i n g rear bearing r e t a i n e r t o
case.
(3) P u l l yoke r e a r w a r d t o s t a r t rear o u t p t shaft out
of clutch.
(4) Remove yoke n u t , washer, seal washer a n d
yoke.
(5) Remove rear retainer, rear o u t p u t shaft a n d
gears as assembly.
(6) Remove rear seal retainer from b e a r i n g r e -
t a i n e r .
(7) Remove snap r i n g .
(8) Remove rear bearing retainer.
(9) Remove rear bearing, speedometer gear, shaft
support bearings, t h r u s t washer p i n a n d l o w gear
f r o m rear o u t p u t shaft ( F i g . 4).
(10) Remove lock r i n g , t h r u s t washer a n d p i l o t
b e a r i n g rollers from rear o u t p u t shaft ( F i g . 4).
FRONT OUTPUT SHAFT
RETAINER
REMOVAL
(1) Remove front yoke n u t , washer and flange ( F i g .
4).
(2) Remove front seal retainer and gasket.
(3) Remove P T O cover a n d gasket.
(4) Remove detent p l u g a n d 4 W D indicator l i g h t
s w i t c h from case (Fig. 4).
(5) Remove shift r a i l detent springs and balls ( F i g .
4) . Use pencil magnet t o remove these components.
(6) Remove bolts a t t a c h i n g front bearing r e t a i n e r
to case.
(7) T a p front o u t p u t shaft w i t h plastic m a l l e t t o
loosen i t . Then remove shaft, retainer and gears ( F i g .
5) .
(8) Remove shaft snap r i n g (Fig. 6).
(9)
Remove t h r u s t washer,
gear, bearings a n d
spacer.
SHIFT RAIL-IDLER
GEAR-INPUT
GEAR-FRONT
SHAFT
REMOVAL
(1) Remove adapter a n d gasket.
(2) Remove idler shaft n u t and washer.
(3) Remove i d l e r shaft cover plate a n d gasket.
(4) Remove cup plugs a t top of case for access t o
shift fork lock pins. Use s m a l l punch t o remove
plugs.
(5) Place shift r a i l s i n N e u t r a l position.
(6) Remove lock pins f r o m shift forks w i t h l o n g
handle easy-out tool ( F i g . 7).
(7) Remove pins a t t a c h i n g shift r a i l l i n k a n d re-
move l i n k .
(8) Remove shift forks a n d sliding clutches.
Fig. 5 Removing/Installing Front Output Shaft
Fig. 7 Removing/Installing Shift Fork Lock Pins
(9) Remove snap r i n g , t h r u s t washer a n d bearing
from front shaft.
Advertisement
Table of Contents
