Pinion clutch assy
1. Remove the 7 pinion clutch mounting bolts.
2. Tap the flange with a plastic mallet and remove the pinion clutch assembly.
3. Remove the drive gear clutch shim.
4. Loosen the pinion nut.
5. With a punch (special tool) press the drive gear out of the clutch.
6. Remove drive gear assembly.
7. Remove the O-ring.
8. Using a screwdriver or similar tool, remove the oil seal.
Caution: Be careful not to damage the pinion clutch.
9. Remove the pinion rear bearing inner race.
10. Using a puller (special tool) Remove the drive gear rear bearing outer race.
11. Using a puller (special tool) Remove the front drive gear bearing outer race.
12. Remove the spacer from the drive gear.
13. Using the special tool, press out the front bearing inner race from the drive gear.
Adapter housing
1. Unscrew the mounting bolts of the adapter housing.
2. Remove the adapter body by lightly tapping it with a plastic mallet.
3. Remove the O-ring.
4. Using a screwdriver or similar tool, remove the oil seal.
Caution: Be careful not to damage the adapter body.
5. Using a brass pin or similar tool, tap the shim through the slot in the adapter body. Remove the shim and the ring gear bearing outer race.
6. Remove the oil trough.
7. Remove the drain plug.
Drive gear assembly
1. Remove the adapter body.
2. Remove the drive gear assembly from the transfer case housing.
3. With a punch (special tool) and a suitable puller, press out the ring gear bearing inner race from the side of the adapter housing.
With the help of a punch (special tool) and a suitable puller, press out the ring gear bearing inner race from the transfer case housing side.
5. With a punch (special tool) and suitable pullers, remove the speedometer drive gear.
6. Turn off fixing bolts of a driving gear wheel.
7. Remove the drive gear from the ring gear by lightly tapping it with a plastic mallet.
8. Using a puller (special tool) remove the seal from the ring gear.