TRANSFER CASE REAR OIL SEAL REPLACEMENT


  1. REMOVE TAIL EXHAUST PIPE ASSEMBLY


    1. A01EMFK

      Remove the 2 bolts and 2 compression springs.

    2. Remove the tail exhaust pipe assembly from the 4 exhaust pipe supports.

    3. Remove the gasket from the center exhaust pipe assembly.

  2. REMOVE CENTER EXHAUST PIPE ASSEMBLY


    1. A01EKUF

      Remove the 2 bolts.

    2. Remove the center exhaust pipe assembly from the 2 exhaust pipe supports.

    3. Remove the gasket from the center exhaust pipe assembly.

  3. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY


    1. Depress the brake pedal and hold it.

    2. A01EIP4E01
      Text in Illustration
      *1 Piece of Cloth

      Using a hexagon wrench (6 mm), loosen the cross groove joint set bolts 1/2 turn.

      Note


      • Put a piece of cloth or equivalent into the inside of the universal joint cover so that the boot does not touch the inside of the universal joint cover.

      • Do not remove the bolts.

    3. A01EMABE01
      Text in Illustration
      *1 Matchmark

      Place matchmarks on the rear propeller shaft and electromagnetic control coupling assembly.

    4. A01EJS9E01

      Remove the 4 nuts and 4 washers.

    5. A01ELS3

      Using a brass bar and a hammer, separate the propeller with center bearing shaft assembly.

    6. A01EM4R

      Remove the 4 bolts, 2 No. 1 center support bearing washers and 2 No. 2 center support bearing washers.

      Note

      When removing the bolts and washers, do not apply excessive force to the universal joint.

    7. Pull out the propeller with center bearing shaft assembly from the transfer.

      Note


      • When removing the propeller shaft, do not apply excessive force to the universal joint.

      • During and after the removal of the propeller shaft, keep the universal joint angle straight (within 15 degrees).

      • Be careful not to damage the oil seal.

    8. A01EK8YE01

      Insert SST into the transfer to prevent oil leaks.

      SST
      09325-20010

      Note

      Be careful not to damage the oil seal.

  4. REMOVE TRANSFER CASE REAR OIL SEAL


    1. A01EMLCE01

      Using SST, remove the transfer case rear oil seal from the transfer extension housing sub-assembly.

      SST
      09308-00010

      Note

      Be careful not to damage the oil seal contact surface or the inside surface of the oil seal.

  5. INSTALL TRANSFER CASE REAR OIL SEAL


    1. A01EMNYE01

      Using SST and a hammer, drive in a new transfer case rear oil seal into the transfer extension housing sub-assembly until it reaches the position shown in the illustration.

      SST
      09325-20010
      Drive in depth
      1.1 to 1.9 mm (0.0433 to 0.0748 in.)

      Note

      Do not tilt the oil seal during installation.

    2. Apply a small amount of MP grease to the lip of the oil seal.

  6. TEMPORARILY TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY


    1. A01EK8YE01

      Remove SST from the transfer.

      SST
      09325-20010

    2. Install the propeller with center bearing shaft assembly.

      Note


      • Be careful not to damage the oil seal.

      • Be careful not to damage the universal joint boot when installing the propeller shaft.

    3. A01EMABE01
      Text in Illustration
      *1 Matchmark

      Align the matchmarks on the rear propeller shaft and electromagnetic control coupling assembly and install the 4 nuts and 4 washers temporarily.

      Note

      Do not allow grease to adhere to be bolts or washers.

    4. A01EM4R

      Temporarily install the propeller with center bearing shaft assembly with the 4 bolts, 2 No. 1 center support bearing washers and 2 No. 2 center support bearing washers.

      Note


      • Reuse the washers.

      • Do not allow grease to adhere to be bolts or washers.

    5. A01EJS9E01

      Fully tighten the 4 nuts.

      Torque:
      37 N*m  { 379 kgf*cm, 27 ft.*lbf }

  7. FULLY TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

    SST
    09370-50010

    1. Remove the piece of cloth or equivalent from the universal joint.

    2. Depress the brake pedal and hold it.

    3. A01EKBT

      Using a hexagon wrench (6 mm), tighten the 6 bolts.

      Torque:
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }
    4. A01EK2SE01

      With the vehicle unloaded, adjust the dimension between the rear side of the cover and shaft as shown in the illustration.

      Length A
      65.5 to 70.5 mm (2.579 to 2.776 in.)
    5. A01EJ81E02
      Text in Illustration
      *1 No. 1 Center Support Bearing Assembly
      *2 No. 2 Center Support Bearing Assembly

      With the vehicle unloaded, adjust the front and rear dimensions between the edge surface of the center support bearing and the edge surface of the cushion respectively as shown in the illustration, and then tighten the bolts.

      Length A
      11.5 to 13.5 mm (0.453 to 0.532 in.)

    6. Check that the center line of the bracket is at a right angle to the shaft axial direction.

    7. A01EM4R

      Fully tighten the 4 bolts.

      Torque:
      37 N*m  { 375 kgf*cm, 27 ft.*lbf }

  8. INSTALL CENTER EXHAUST PIPE ASSEMBLY


    1. Install a new gasket to the center exhaust pipe assembly.

    2. Connect the center exhaust pipe assembly to the 2 exhaust pipe supports.

    3. A01EKUF

      Install the center exhaust pipe assembly with the 2 bolts.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  9. INSTALL TAIL EXHAUST PIPE ASSEMBLY


    1. A01EMBG

      Using a vernier caliper, measure the free length of the compression springs.

      Minimum length
      38.5 mm (1.52 in.)

      If the free length is less than the minimum, replace the compression spring.

    2. Fully insert a new gasket to the center exhaust pipe assembly.

    3. A01EMPOE17
      Text in Illustration
      *1 Center Exhaust Pipe Assembly
      *2 Gasket
      *3 Wooden Block

      Using a plastic hammer and wooden block, tap in the new gasket until its surface is flush with the center exhaust pipe assembly.

      Note


      • Be sure to install the gasket in the correct direction.

      • Do not reuse the gasket.

      • Do not damage the gasket.

      • Do not push in the gasket by using the exhaust pipe when connecting it.

    4. Connect the tail exhaust pipe assembly to the 4 exhaust pipe supports.

    5. A01EMFK

      Install the tail exhaust pipe assembly with the 2 bolts and 2 compression springs.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  10. INSPECT TRANSFER OIL


    1. A01ELNB

      Remove the No. 1 transfer case plug and gasket.

    2. A01EKXT

      Check that the oil level is between 0 and 5 mm (0 and 0.197 in.) from the bottom lip of the case plug hole.

      Note


      • When inspecting the transfer oil, make sure the vehicle is level.

      • An excessively large or small amount of oil may cause damage.

      • After adding oil, drive the vehicle and recheck the oil level.

    3. Check for oil leakage if the oil level is low.

    4. Install a new gasket onto the No. 1 transfer case plug and then tighten the plug.

      Torque:
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }

  11. INSPECT EXHAUST GAS LEAK