TRANSFER ASSEMBLY DISASSEMBLY


  1. REMOVE TRANSFER COVER GASKET


    1. A017BHG

      Remove the transfer cover gasket from the transfer assembly.

  2. REMOVE TRANSFER CASE BREATHER PLUG


    1. A017FEU

      Using a screwdriver and a hammer, remove the transfer case breather plug from the No. 1 transfer case cover.

      Note

      Be careful not to damage the contact surface of the No. 1 transfer case cover.

  3. REMOVE NO. 1 TRANSFER CASE COVER


    1. A017C3X

      Remove the 8 bolts.

    2. A017DNE

      Using a brass bar and a hammer, remove the No. 1 transfer case cover from the transfer case.

      Note

      Be careful not to damage the contact surfaces of the case and cover.

  4. REMOVE BREATHER OIL DEFLECTOR


    1. A017CV7

      Remove the bolt and breather oil deflector from the No. 1 transfer case cover.

  5. REMOVE TRANSFER DYNAMIC DAMPER


    1. A017DSF

      Remove the 3 bolts and the transfer dynamic damper from the transfer extension housing sub-assembly.

  6. REMOVE TRANSFER CASE STRAIGHT PIN


    1. Remove the 4 transfer case straight pins from the transfer case.

  7. REMOVE TRANSFER AND TRANSAXLE SETTING STUD BOLT


    1. Remove the 4 transfer and transaxle setting stud bolts.

  8. FIX TRANSFER ASSEMBLY


    1. Fix the transfer assembly to the overhaul attachment.

  9. REMOVE TRANSFER EXTENSION HOUSING DUST DEFLECTOR


    1. A017DUB

      Using a plastic hammer, remove the transfer extension housing dust deflector from the transfer extension housing sub-assembly.

  10. REMOVE TRANSFER EXTENSION HOUSING TYPE T OIL SEAL


    1. A017C8CE02

      Using SST, remove the transfer extension housing type T oil seal from the transfer extension housing.

      SST
      09308-00010

      Note

      Be careful not to damage the oil-seal-fitted surface of the housing and the inside surface of the bush.

  11. REMOVE TRANSFER EXTENSION HOUSING SUB-ASSEMBLY


    1. A017DYS

      Remove the 4 bolts.

    2. A017ELI

      Using a plastic hammer, remove the transfer extension housing sub-assembly from the transfer case.

  12. INSPECT PRELOAD


    1. A017FHUE10

      Using SST and a torque wrench, check the initial torque with the backlash range.

      SST
      09326-20011
      Torque:
      0.9 to 1.4 N*m  { 9 to 14 kgf*cm, 8.0 to 12.4 in.*lbf }

      Tech Tips

      Use a torque wrench with a fulcrum length of 160 mm (6.30 in.).

    2. Using SST and a torque wrench, check the initial torque while the driven pinion is in contact with the ring gear face.

      SST
      09326-20011
      Torque:
      Preload
      1.07 to 1.68 N*m  { 10.9 to 17.1 kgf*cm, 9.5 to 14.9 in.*lbf }

      Tech Tips

      Use a torque wrench with a fulcrum length of 160 mm (6.30 in.).

  13. REMOVE CENTER DIFFERENTIAL LOCK SLEEVE


    1. A017CEP

      Using snap ring pliers, remove the shaft snap ring.

    2. A017DCAE02

      Using SST, remove the CTR differential lock sleeve.

      SST
      09308-00010

  14. REMOVE O-RING


    1. A017C58

      Using a screwdriver with the tip protected by vinyl tape, remove the O-ring from the CTR differential lock sleeve.

      Note

      Be careful not to damage the lock sleeve's groove for the O-ring.

  15. REMOVE TRANSFER CASE OIL SEAL


    1. A017F3QE03

      Using SST, remove the transfer case oil seal from the case.

      SST
      09308-00010

      Note

      Be careful not to damage the oil-seal-fitted surface of the case.

  16. REMOVE TRANSFER RH BEARING RETAINER OIL SEAL


    1. A017DBQE02

      Using SST, remove the transfer RH bearing retainer oil seal from the transfer RH bearing retainer sub-assembly.

      SST
      09308-00010

      Note

      Be careful not to damage the oil-seal-fitted surface of the retainer.

  17. REMOVE TRANSFER RH BEARING RETAINER SUB-ASSEMBLY


    1. A017F1J

      Remove the 7 bolts from the transfer RH bearing retainer sub-assembly.

    2. A017EUGE01

      Using SST, make a clearance between the transfer RH bearing retainer sub-assembly and the transfer case.

      SST
      09950-00020

    3. Remove SST.

    4. A017CYXE06

      Using SST, remove the transfer RH bearing retainer sub-assembly from the transfer case.

      SST
      09520-10021

  18. REMOVE O-RING


    1. A017D7N

      Using a screwdriver with the tip protected by vinyl tape, remove the 2 O-rings from the transfer RH bearing retainer sub-assembly.

      Note

      Be careful not to damage the retainer's grooves for the O-rings.

  19. REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING


    1. A017FEKE02

      Fix the transfer RH bearing retainer sub-assembly in a vise.

    2. Using SST, remove the center differential case tapered roller bearing RH outer race, No. 2 transfer ring gear mounting case washer and No. 2 transfer RH bearing retainer oil seal from the transfer RH bearing retainer sub-assembly.

      SST
      09308-00010

      Note

      Be careful not to damage the oil-seal-fitted surface of the transfer RH bearing retainer sub-assembly.

  20. REMOVE SIDE GEAR SHAFT HOLDER BEARING


    1. A017C1Z

      Using snap ring pliers, remove the side gear shaft holder hole snap ring.

    2. Remove the side gear shaft holder bearing from the transfer RH bearing retainer sub-assembly.

  21. REMOVE TRANSFER RING GEAR MOUNTING CASE


    1. A017C8F

      Remove the transfer ring gear mounting case from the transfer case.

  22. REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING

    SST
    09950-40011   ( 09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011 )
    09950-60010   ( 09951-00430 )

    1. A017DMDE02

      Using SST, remove the inner race of the center differential case tapered roller bearing from the transfer ring gear mounting case.

      Note

      Apply grease to the screw thread and tip of SST before use.

    2. A017G4FE02

      When the roller comes off due to deformation of the gauge, completely remove the roller and remaining inner races of the center differential case tapered roller bearing from the transfer ring gear mounting case.

      SST
      09950-00020
      09950-00030
      09950-60010   ( 09951-00430 )

      Note

      Apply grease to the screw thread and tip of SST before use.

    3. A017GBXE02

      Using SST, remove the inner race of the center differential case tapered roller bearing from the transfer ring gear mounting case.

      SST
      09950-40011   ( 09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011 )
      09950-60010   ( 09951-00360 )

      Note

      Apply grease to the screw thread and tip of SST before use.

    4. A017F5TE02

      When the roller comes off due to deformation of the gauge, completely remove the roller and remaining inner races of the center differential case tapered roller bearing from the transfer ring gear mounting case.

      SST
      09950-00020
      09950-00030
      09950-60010   ( 09951-00360 )

      Note

      Apply grease to the screw thread and tip of SST before use.

  23. REMOVE RING GEAR


    1. A017EE8E03

      Put matchmarks on the transfer ring gear mounting case and the ring gear.

    2. Remove the 12 bolts.

    3. A017FCY

      Using a plastic hammer, remove the ring gear by tapping around its periphery.

      Note

      Do not damage the teeth of the ring gear.

  24. REMOVE TRANSFER GEAR NUT


    1. A017DMUE02

      Using SST and a hammer, unstake the transfer gear nut.

      SST
      09930-00010
    2. A017ERTE02

      Using SST, remove the transfer gear nut.

      SST
      09326-20011
      09556-16030
    3. A017FQG

      Using a press, remove the driven pinion, transfer driven pinion rear bearing inner race and transfer pinion bearing spacer.

      Note


      • Put shop cloths around the transfer case to help prevent the driven pinion from dropping out of the bearing.

      • Place something like wooden blocks under the case to keep its level.

  25. REMOVE TRANSFER DRIVEN PINION FRONT BEARING


    1. A017C5ZE02

      Using SST and a press, remove the transfer driven pinion front bearing inner race from the driven pinion.

      SST
      09950-00020

  26. REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING


    1. A017FAH

      Using a brass bar and a hammer, lightly strike the center differential case tapered roller bearing LH outer race at 2 positions to remove it from the transfer case.

  27. REMOVE TRANSFER OUTPUT SHAFT WASHER


    1. Remove the ring gear mounting case plate washer from the transfer case.

  28. REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING


    1. A017BIO

      Using a brass bar and a hammer, lightly strike the transfer driven pinion front bearing outer race at 2 points to remove it from the transfer case.

  29. REMOVE RING GEAR MOUNTING CASE PLATE WASHER


    1. Remove the transfer output washer from the transfer case.

  30. REMOVE TRANSFER DRIVEN PINION REAR BEARING


    1. A017DK2

      Using a brass bar and a hammer, lightly strike the transfer driven pinion rear bearing outer race at 2 points to remove it from the transfer case.