TRANSFER CASE FRONT OIL SEAL REPLACEMENT


  1. DRAIN TRANSFER OIL

    A01DUI3

    1. Remove the filler plug and gasket.

    2. Remove the drain plug and gasket, and drain the transfer oil.

  2. REMOVE FRONT PROPELLER SHAFT ASSEMBLY


    1. Remove the front propeller shaft Click here.

  3. REMOVE FRONT OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY


    1. Using a chisel and hammer, loosen the staked part of the lock nut.

    2. A01DSBQE04
      Text in Illustration
      *a Turn
      *b Hold

      Using SST to hold the front output shaft companion flange sub-assembly, remove the lock nut.

      SST
      09330-00021
    3. A01DNHWE01

      Using SST, remove the companion flange.

      SST
      09950-40011   ( 09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04051, 09957-04010, 09958-04011 )

  4. REMOVE FRONT TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL


    1. Using a screwdriver and hammer, tap out the oil seal from the companion flange.

      Note

      Be careful not to damage the oil seal and companion flange contact surfaces.

  5. REMOVE TRANSFER CASE FRONT OIL SEAL

    A01DT9RE01

    1. Using SST, tap out the oil seal.

      SST
      09308-00010

      Note

      Be careful not to damage the oil seal and front case contact surface.

  6. INSTALL TRANSFER CASE FRONT OIL SEAL

    A01DSJ5E01

    1. Coat the lip of a new oil seal with MP grease.

    2. Using SST and a hammer, tap in the oil seal until its metal ring contacts the case.

      SST
      09649-17010
      09950-70010   ( 09951-07100 )

  7. INSTALL FRONT TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL


    1. A01DNVDE02

      Using SST and a hammer, tap in a new oil seal.

      SST
      09950-60010   ( 09951-00320 )
      09950-70010   ( 09951-07100 )

    2. Coat the lip of the oil seal with MP grease.

  8. INSTALL FRONT OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY

    A01DURVE01

    1. Apply gear oil to the connecting areas of the companion flange and driven sprocket.

    2. Install the companion flange to the driven sprocket.

      Text in Illustration
      A01DQPB Front

    3. Using SST to hold the companion flange, install a new lock nut.

      SST
      09330-00021
      Torque:
      118 N*m  { 1203 kgf*cm, 87 ft.*lbf }
    4. A01DQWIE02
      Text in Illustration
      *a Correct
      *b Incorrect

      Using a chisel and hammer, stake the lock nut.

      Note


      • Securely stake the shaft to the lock nut groove.

      • Be careful not to damage the parts around the lock nut.

      • Do not apply excessive force to the shaft.

  9. INSTALL FRONT PROPELLER SHAFT ASSEMBLY


    1. Install the front propeller shaft Click here.

  10. ADD TRANSFER OIL


    1. Remove the filler plug and gasket.

    2. Add oil so that the oil level is between 0 to 5.0 mm (0 to 0.196 in.) from the bottom lip of the filler plug hole.

      Note


      • Add oil slowly.

      • Add oil a little at a time, waiting several minutes between each addition of oil.

    3. Wait approximately 5 minutes and check that the oil level has not changed.

    4. Install a new gasket to the filler plug and then tighten the plug.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

  11. CHECK FOR TRANSFER OIL LEAK