Yes, you can remove the front output housing without taking the transfer case or gearbox out.
The most likely reason for the failure however, apart from obvious problems such as the pivot for the lever that the yellow knob operates having fallen out, is that lack of use of four wheel drive has resulted in the selector shafts becoming seized. You may be able to free them without further disassembly by removing the dust cover that protects the front ends of the selector shafts and cleaning them and applying penetrating oil over several days.
Less likely, and requiring the extension housing to be removed, is something in the mechanism loose or broken, most likely the pivot for the link between the selector shafts, or possibly a broken spring.
All of this involves removing the driver's floor and the use of the workshop manual (if necessary look for the "RaveCD" in "shop" at the top of this page).
Hope this helps.
John
Last edited by JDNSW; 2nd September 2011 at 09:32 AM.
Reason: Forgot to close bracket
John
JDNSW
1986 110 County 3.9 diesel
1970 2a 109 2.25 petrol
Bookmarks