Overhaul

10. Remove the front and rear companion flanges.

11. Remove the extension housing.
12. Remove the speedometer drive gear, steel ball, oil pump
screw and bearing.
13. Remove the rear case half with the idler gear in position, while
holding the front half so that the clutch hub and steel ball do not fall
out.
14. Remove the idler gear from the rear case.
15. Remove the front bearing retainer and front drive gear.
16. Remove the 2 oil pipes.
17. Remove the No. 1 shift fork and clutch sleeve.
18. Remove the clutch hub and transfer drive gear. Remove the
needle roller bearing, No. 2 spacer and steel ball. On models with
the 22R engine, remove the transfer case cover and shift lever
retainer.
19. Remove the screw cover plugs, springs and locking balls from
both sides of the case.
20. Remove the spring pins that retain the shift forks and remove
the front shift fork shaft. Remove the interlocking pin and high/low
fork.
21. Remove the front case, tapping lightly with a plastic mallet.
22. Remove the No. 2 shift fork, clutch sleeve and needle roller
bearing from the input shaft.
23. Remove the input gear and countergear from the reduction
gear case. Remove the output shaft from the front case.
24. Check the oil seal and thrust clearance of the transfer low
gear. The clearance between the gear and shaft, with the needle
bearing installed, should be 0.010-0.056mm. The thrust clearance
with the spacer and bearing installed should be 0.010-0.25mm.
25. Check the thrust drive gear clearance. Clearance between the
gear and shaft with the needle bearing installed should be 0.010-
0.050mm. Thrust clearance with the clutch hub and spacer
installed should be 0.089-0.270mm.
26. Measure the clearance between the shift forks and clutch
sleeves. Clearance should be 1mm max.
27. Inspect all parts. Replace any worn or damaged parts. If the
bearings are to be replaced, you'll need an arbor press to remove
and install them. When installing bearings, use the thickest
possible snapring to insure minimum end-play.
To assemble
28. Place the output shaft in the front case.
29. Install the front bearing retainer and torque the bolts to 10 ft.
lbs.
30. Install the input gear and countergear in the reduction case.
31. Install the roller bearing on the input shaft.
32. Install the No. 2 hub sleeve and No. 2 shift fork on the input
shaft.
 33. Install the reduction gear case and new gaskets on the front
case. Torque the bolts to 30 ft. lbs.
Two different length bolts are used. May sure you get them in the correct holes.
34. Install the front drive gear, bearing retainer and new gasket.
Torque the bolts to 14 ft. lbs.
35. Install the high/low shift fork, the interlock pin and front drive
shift fork shaft.
36. Install the slotted spring pins. Install the balls, springs and side
plugs. Tighten the plugs to 10 ft. lbs.
37. Install the locking ball and No. 2 spacer. Install the needle
roller bearing, transfer low gear and clutch hub.
38. Install the No. 1 shift fork and hub sleeve.
39. Install the oil pipes.
40. Install the idler gear in the rear case.
41. Using anew gasket, install the rear case. Torque the bolts to
30 ft. lbs.
Two different length bolts are used. May sure you get them in the correct holes.
42. Install the bearing, oil pump screw, locking ball and
speedometer drive gear.
43. Install the extension housing with a new gasket. Torque the
bolts to 30 ft. lbs.
44. On trucks equipped with the 22R engine, install the transfer
case cover and shift lever retainer.
45. Install the front and rear flanges. Torque the fasteners to 90 ft.
lbs.
46. Install the indicator switch and speedometer driven gear.

Transfer case components

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Transfer case components

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