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Bonus points if you wash the 'case in your gf's bathtub!
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Begin by removing the rear yoke or companion flange
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Now remove the bolts which hold the rear tailshaft housing on
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Now you'll find a c-clip behind the speedo drive gear - remove this
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Here you can just make out the BB which locates the speedo drive gear. Remove this and store carefully
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I used my bearning splitter to pull the drive gear off, but you can use long screwdrivers or pry bars *if you're careful*
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You can just make out the notch in the drive gear that the BB uses to locate it
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Now you must remove this snap ring; be sure you have _quality_ snap ring pliers. I eventually went to Snap On.
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Now you may remove the bolts which anchor the case halves. Carefully slide the back half off to expose what you see above.
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Now remove the front output yoke
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As a note of interest, here you can see the oil pump locator arm and the notch in the case in which it resides (and eventually eats thru)
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This is what happens to the oil pump locator arm if it eats thru the 'case
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Here's one (good) way to prevent oil pump failure. The rod increases contact area and makes it much harder to wear thru the 'case
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This is the oil pump pickup. Black rectangular magnet underneath it slides into a notch in the case
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You can now slide the front and rear cogs back toward you, bringing the chain with it. Here you see the rear assembly removed from the planetary gears (still in the case)
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This is the high range/neutral/low range selector. Note the shift fork pads (white) in which it always spins.
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Here you see what happens if the shift fork pads wear thru; this 'case had 208k miles on it
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Now flip the front case half over and pry out the front input seal to reveal this snap ring. Be certain you have a nice pair of duckbill snap ring pliers to spread this one
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Duckbill pliers as mentioned above
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Remove this large "snap ring" and the planetary assy will drop out
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Some of the bearings are retained with internal snap rings like this
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I pulled the tailshaft bearing out like so
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The needle bearings which support the rear of the front output were difficult to remove. I finally cut most of the cage with my Dremel (there's a notch in the case which helps) and then yanked it with my slide hammer
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The internals of the oil pump assy
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Here's all the rebuild parts I ordered. Top: seals and bearings, lower left new Morse chain, lower right new oil pump assy
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Here's most of the tools I used. Note the nice, large red-handled Snap-On snap ring pliers
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All done in the gf's spare bedroom
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