TRANSFER CASE REAR 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 REAR PROPELLER SHAFT ASSEMBLY


    1. Remove the rear propeller shaft Click here.

  3. REMOVE REAR OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY


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

    2. A01DSKZE01

      Using SST to hold the companion flange, remove the lock nut.

      SST
      09330-00021
    3. A01DQGFE01

      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 REAR 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 REAR OIL SEAL

    A01DRVUE01

    1. Using SST, tap out the oil seal.

      SST
      09308-00010

      Note

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

  6. INSTALL TRANSFER CASE REAR OIL SEAL

    A01DT0ME01

    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 surface is flush with the case upper surface.

      SST
      09223-46011
      09631-32020

  7. INSTALL REAR 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 REAR OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY


    1. A01DR12E01

      Apply gear oil to the connecting areas of the companion flange and output shaft.

    2. Install the companion flange to the output shaft.

      Text in Illustration
      A01DQPB Rear

    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 PROPELLER SHAFT ASSEMBLY


    1. Install the rear 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