Jeep J-10 Series 1982 Technical & Service Manual page 719

INPUT
SHAFT
BEARING
90775
Fig. 20-77 Front Support. Input Shaft and
Rear Output Shaft Gear Removal/Installation
(5) Remove rear output shaft clutch sleeve from
case.
(6) Remove and discard snap ring retaining rear
output shaft gear on input shaft and remove gear.
(7) Remove and discard input shaft bearing snap
ring.
(8) Remove input shaft and bearing from support.
Tap end of input shaft with plastic mallet to aid
removal.
(9) Remove input shaft bearing and end play shims
from shaft using arbor press.
(10) Remove input shaft oil seal from support. Dis
card seal.
(11) Remove intermediate shaft lockplate bolt and
lockplate (fig. 2D-76).
(12) Remove intermediate shaft. Tap shaft out of
case using brass punch and plastic mallet.
(13) Remove and discard intermediate shaft O-ring
seal.
(14) Remove intermediate gear assembly and thrust
washers.
NOTE: Thrust washers have locating tabs which must
fit in notches in the case at assembly.
(15) Remove needle bearings and bearing spacers
from intermediate gear.
TRANSFER CASE 2D-43
NOTE: There are 48 needle bearings and three bearing
spacers in the intermediate gear.
(16) Remove rear bearing cap attaching bolts and
remove cap. Use plastic mallet to tap on output shaft to
aid cap removal.
NOTE: The rear bearing cap has been coated with a
sealant. Use a putty knife to break the seal, and work
the knife around the cap to loosen and remove it.
(17) Remove end play shims and speedometer drive
gear from rear output shaft (fig. 2D-76).
(18) Remove and discard rear output shaft oil seal.
Remove bearings and bearing races from rear bearing
cap.
(19) Remove setscrews retaining front and rear out
put shaft shift forks on shift rods (fig. 2D-78).
(20) Remove shift rods. Insert punch through clevis
pin holes in rods and rotate rods while pulling them out
of case.
NOTE: When the shift rods are free of the front cap
take care to avoid losing the shift rod poppet balls and
springs.
(21) Remove shift forks from case.
(22) Remove bolts attaching front cap-to-case and
remove front cap.
NOTE: The front cap has been coated with a sealant.
Use a putty knife to break the seal, and work the knife
around the cap to loosen and remove it.
(23) Remove front output shaft and shift rod oil seals
from front cap (fig. 2D-76). Discard seals.
(24) Remove front bearing race from front bearing
cap using Tool J-29168.
n
X^SS
5S**e&**f * -'
• V
Fig. 2D-78 Shift Fork Setscrew Removal/Installation
90776