Ok, I will do my best to show this rebuild in great detail so other members can benefit. I could of used something like this when I redid the last 2. There are two helpful ones on here but neither is totally complete. Thanks Photo Bucket. I will also show the tools I used to get this done. I am following the FSM step by step for the most part. I am sure there are other ways to get this done but this way has worked for me. Please feel free to comment or ask any questions. The 2 bearing separators are OTC 1122, and 1123. The big bearing puller is a posi-lock TJ-1. The one puller I do not have is my small 3 jaw posi-lock, its at work. The snap ring pliers are from The Snap On truck at work. I am not a brand snob but these are heavy duty and make the rebuild easier. Some of the snap rings in the trans are pretty beefy and my regular pliers didn't quite cut it. These are the only real specialty tools I used. Plus the one I had to make

 

I like to start this way. with the trans out you already have the shifter removed. Remove the bolt in the shift shaft

 

Remove the bolts from the transfer case adapter to transmission. I use a stiff putty knife and a small pry bar to get the t/c adapter moving

 

This is what you should have now with the T/C adapter removed

 

Sometimes this shift shaft falls when you pull the adapter if not remove it now, its just sitting there.

 

Remove the 9 bell housing bolts. And the seven bearing retainer bolts

 

Remove the 2 snap rings on the bearings. And yes the front shaft should be able to move in and out about 1/4"

 

This is the second snap ring

 

Now this is where you are getting to remove the transmission case. Using a rubber mallet tap the corners of the case. once you get it moving I hold down on the output shaft and work the case off

 

Now the you have the cases off i clamp it a vise as the FSM suggests but i don't put bolts thru the bottom, I clamp it in between 2 pieces of 3/4" plywood

 

Now that I have it this far torn down I think I know why it was popping out of gear, the main bearing is toast there is a ton of movement it in. I didn't see any metal when draining oil. this trans only has 120,000 original miles.

 

Just some pics of the trans

 

the other side

 

First I remove these two bolts. And on the right side of the pic, I call it spring ball #2, just easier for me to keep track ok

 

This is the way the FSM shows removing these small snap rings. notice the magnet on the bottom, it helps not to lose the ring when you pop it off

 

You can remove this reverse idler shaft lock

 

Now you can pull the reverse idler shaft, but look where my finger is pointing to a small groove where there is a detent pin

 

this is that pin

 

There is a total of 4 of these pins. they are all different and critical to get in the right place

 

you can now remove the #1 shift fork shaft and the clips on the #2 shift fork shaft. Even using the magnet i lost this snap ring tonight