SAFARI

TRANSFER CASE

REMOVAL OF TRANSFER CASE FROM

VEHICLE

Place chocks on wheels.

Disconnect battery terminals, electrical connections

of starter motor and remove starter motor.

Remove rubber bellow from collar of base plate.

Loosen lock nut and remove gear shift lever knob.

Take out rubber bellow.

Remove screws and take out clamping plate of the

rubber bellow - bottom.

Disconnect exhaust pipe frommanifold end and main

muffler.

Disconnect extension arm support bracket from

transfer case housing.

Disconnect electrical connector of electrical shift motor

and speed sensor.

Disconnect electrical connector of vehicle speed

sensor, In case of petrol engine.

Disconnect front and rear propeller shaft at transfer

case end.

Slide the propeller shaft side ways and support it

suitably.

Remove circlip from both ends of shift link and take it

out along with teflon washers.

Remove circlip and take out pin along with Teflon

washer to disconnect extension arm from extension

arm bracket. Remove extension arm assembly.

Disconnect and remove clutch slave cylinder from

clutch housing.

Disconnect speedo cable and connector from reverse

indicator switch.

Remove clutch housing front sheet metal cover.

Loosen and remove clutch housing mounting bolts.

Loosen and remove gear box adaptor housing support

- Rear mounting bolts.

Lift the transfer case, gear box assembly from rear

and support the engine suitably.

Remove cross member supporting gear box, from the

chassis.

Pull out gear box along with transfer case to disengage

drive shaft from the clutch plate splines.

Lower the assembly carefully.

Loosen the adaptor housing bolts and separate gear

box and transfer case.

Note :

Install the transfer case by taking guideline

from the above write - up.