IV. TRANSFER CASE DISASSEMBLYImportant: Read this section before starting the disassembly procedures.A.General Precautions for Disassembly1.After removing the transfer case from the vehicle,remove any mounting brackets still attached to thetransfer case.2.The outside of the unit should be cleaned beforestarting the disassembly. If steam cleaning, ensurethat breather and air fittings are covered to preventwater from entering assembly.5.Assemblies - When disassembling the variousassemblies, lay all parts on a clean bench in thesame sequence as removed. This procedure willsimplify reassembly and reduce the possibility of lostparts.6.When necessary to apply a force to remove a part,use of a puller or press would be preferred.However, sometimes it may be necessary to use asoft hammer or mallet.3.Cleanliness provide a clean place to work. It isimportant that no dirt or foreign material enters theunit during repairs.4.Position the transfer case horizontally, with the coverplate facing upwards. A specially fabricated stand isdesirable.7.Bearings Carefully wash and relubricate all bearingsas removed and protectively wrap until ready for use.Remove bearings with pullers designed for thispurpose, or in a manner which will not damage thosebearings that will be reused.8.Follow each procedure closely in each section,making use of both text and pictures. Refer toexploded views located in Section VIII.B.Preparation for Disassembly1.Remove locknut and washer from each yoke orcompanion flange on the upper and lower shafts.Remove each companion flange or yoke from itsshaft. A gear puller may be required for yoke orflange removal. Discard the used locknuts andreplace with new nuts at assembly.2.Remove bolts and lockwashers from cover plate.Tap cover plate to loosen and remove.3.Remove hand brake assembly from lower shaft ifcase is so equipped.Fig. 1Fig.2-11-
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