This task covers:
c. Inspection and Repair
General mechanic's tool kit:
Rear output drive seal (Appendix E, Item 240)
input gear seal installer
Input gear bearing installer
Output shaft front bearing remover/installer
Transfer case support stand
Extension bushing remover
Bushing remover/bearing installer
Extension housing seal installer
Output shaft seal installer
Mainshaft pilot bearing installer
Remove capscrew (1), clamp (2), pinion adapter (6), and driven gear (4) from rear retainer (5).
Remove O-ring (3) from pinion adapter (6). Discard O-ring (3).
Remove nut (7), front output yoke (8), and lockwasher (9) from transfer case (11) Discard
Move shift range lever (10) to most rear position.
Remove three capscrews (13) from rear extension (14) and rear retainer (5).
Do not pry or wedge rear extension from rear retainer. Sealing
surfaces could be damaged.
Use a soft nosed hammer or mallet on screw hole bosses (15) of rear extension (14) to break sealing
bead and remove rear extension (14) from rear retainer (5).
Remove rear output drive seal (12) from rear extension (14). Discard rear output drive seal (12).