Ok! All the parts are here so lets get started tearing the
Start by removing the cotter pin holding the
E-brake drum nut in place (See Fig. 1) then
use a impact gun with a 27mm hex socket to take the nut off.
Slide the drum off the shaft. Inspect the seal
area of the drum, if it is grooved you will need to get a speedi sleeve
for it or replace it.
Remove the e-brake shoe springs, adjusters
and levers. The shoes are held on with retainers! See Fig.
Remove the 3 8mm x 1.25 x xxmm bolts plus 1 8mm x 1.25 x
xxmm bolt holding the backing plate on with a 12mm wrench. See Fig.
Remove the 5 8mm x 1.25 x xxmm bolts holding
the speedo housing to the t-case with a 12mm wrench. See Fig.
Tap the housing loose with a rubber mallet
and slide it off the shaft. There will be a set of shims behind the housing.
Do NOT loose these shims! You will re-use them later. See Fig.
Remove the bolt holding the speedo gear.
Slide the gear and shaft out. Inspect the gear for wear. Now is a good
time to order a gear to change the speedo ratio if needed. See Fig.
Slide the speedo drive gear and the spacer
off the shaft. Note the beveled edge of the spacer will go toward the outside
when you reassemble! See Fig. 6.
Removing Companion Flange
Removing Shift Shaft Housing
Removing Extension Housing
Remove the front companion flange cotter pin and use an impact
gun with a 27mm hex or 1 1/8" hex socket to remove the nut. Slide the
flange off the shaft. Don't loose the washer and nut! See Fig.
Make sure the 2WD/4WD shift shaft is pulled all the way OUT.
Use a 12mm wrench to remove the 4, 8mm x 1.25 x 55mm, bolts holding the Shift
Shaft housing to the Extension housing. See Fig. 7.
Use a rubber mallet and tap the housing to loosen it. Separate it from the
extension housing being careful not to break the shift fork. Set it aside
Using a 12mm wrench remove the 5 bolts holding the extension
housing to the T-case. Tap it with a rubber mallet to loosen it. Slide the
extension housing off. See Fig. 8-9.
Use a long screwdriver or punch and pry out the oil seal
in the end of the extension housing. See Fig. 10.
Removing Oil Seal
Removing Bearing Retainer
Refer to Fig. 11 to locate
and remove the spit ring that retains the bearing. This is a bit difficult
you get one end started it comes
Next we need to remove the bearing with the shaft from the
front extension housing. Invert the housing and support the end of the
housing with wood or metal blocks and use a plastic mallet or wood block
or a press
bearing out of the housing. See Fig. 12.
Next remove the bearing from the shaft. If you have a hydraulic
press use a bearing cup to support the bearing and press it off. If you
don't then use two blocks of wood and a plastic mallet or block of wood.
See Fig. 13.
Fig. 14 shows all the Extension Housing parts.
Shift Cover Removed
Removing Shift Fork Spring Retainer
Driving out Shift Fork Shaft
Using a 12 mm wrench remove the 8 8mm x 1.25 x 25mm bolts
holding the top shift cover to the T-case. See Fig. 15.
Remove the cotter pin and use a flat screwdriver to remove
the shift fork spring retainer. Under the retainer is a spring and a metal
ball. A magnet is helpful for removing the ball. See Fig.
Use a punch to drive out the shift shaft. See Fig.
17. Remove the shift fork.