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The detent pin must be removed. The detent pin is what
engages the notches on top of the shift sector and keeps everything locked into
the right position. In the above picture, I am holding the plug, spring,
and detent pin next to the threaded hole it was just removed from.
The above picture is a good view of the mode fork, shift rail, and the mode
sleeve. When you look at the inside workings of the t-case, you should be
able to see how the mode sleeve travels back and forth and engages the gear that
causes the front output shaft to turn. Again, be careful to keep control
of that mode sleeve as it easily slips out of the mode fork.
I included the above picture just to provide another view of how
things fit together. In this show, I have the mode sleeve almost
completely removed from the gear on which is mates. The gear with large
gaps between the teeth (just in front of the drive chain) is the gear that
drives the front output shaft. When the mode sleeve travels back towards
the chain, it engages that gear and locks it with the gear just in front of
it. At that point, you are in 4WD. The position of the range fork
will determine if you are in HI or LO range.
In this picture, I have removed the shift lever from the end of
the shift sector shaft. Set it aside as you will be using it when you put
everything back together.
Gently push the shift sector shaft into the housing a little
ways. There is a nylon bushing and an 0-ring that you must remove from the
end of the hole. Clean these off and put them with the other parts that
will be going into the new rear case. Remember that the o-ring goes in
first and then the nylon bushing.
From the inside of the case, gently pull the shift sector out of the shaft hole. You might have to wiggle it around a bit to get it to clear everything, but it will come out without much trouble. Hang in there....you are almost done scavenging the parts from the old rear case. Just a couple more parts and you will be officially half way done with the project!
More of Round #2