TRANSFER ASSEMBLY DISASSEMBLY


  1. REMOVE TRANSFER AND TRANSAXLE SETTING STUD BOLT


    1. A01ELP1

      Remove the 4 transfer and transaxle setting stud bolts.

  2. REMOVE NO. 2 TRANSFER CASE PLUG


    1. A01EK0K

      Remove the No. 2 transfer case plug.

    2. Remove the gasket from the No. 2 transfer case plug.

  3. REMOVE NO. 1 TRANSFER CASE PLUG


    1. A01EJGT

      Remove the No. 1 transfer case plug.

    2. Remove the gasket from the No. 1 transfer case plug.

  4. REMOVE TRANSFER DRAIN PLUG


    1. A01ELX9

      Remove the transfer drain plug.

    2. Remove the gasket from the transfer drain plug.

  5. REMOVE TRANSFER CASE BREATHER PLUG


    1. A01EJ1N

      Using a screwdriver, remove the transfer case breather plug.

  6. REMOVE NO. 1 TRANSFER CASE COVER


    1. A01EMA0E01

      Remove the 8 bolts.

    2. A01EMDI

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

      Note

      Place the brass bar on the rib protruding from the No. 1 transfer case cover.

  7. REMOVE BREATHER OIL DEFLECTOR


    1. A01EK9M

      Remove the bolt and breather oil deflector.

  8. REMOVE TRANSFER DYNAMIC DAMPER


    1. A01EKPW

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

  9. REMOVE TRANSFER CASE STRAIGHT PIN


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

      A01ELN6E01

  10. SECURE TRANSFER ASSEMBLY


    1. Attach the transfer assembly to an overhaul attachment.

  11. REMOVE TRANSFER EXTENSION HOUSING DUST DEFLECTOR


    1. A01EJ11

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

  12. REMOVE TRANSFER CASE REAR OIL SEAL


    1. A01EKP8E01

      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 transfer case rear oil seal contact surface or the inside surface of the transfer case rear oil seal.

  13. REMOVE TRANSFER EXTENSION HOUSING SUB-ASSEMBLY


    1. A01EKXA

      Remove the 4 bolts.

    2. A01EJVS

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

  14. INSPECT PRELOAD


    1. A01ELWUE01
      Text in Illustration
      *1 No. 2 Transfer Ring Gear Mounting Case Washer

      Using SST and a torque wrench, measure the preload of the backlash between the driven pinion and ring gear.

      SST
      09326-20011
      Preload (at Starting)
      Item Preload
      without SST 0.56 to 0.94 N*m (6 to 9 kgf*cm, 5 to 8 in.*lbf)
      with SST 0.40 to 0.67 N*m (4 to 6 kgf*cm, 4 to 5 in.*lbf)

      Tech Tips


      • Use a torque wrench with a fulcrum length of 130 mm (5.12 in.).

      • Turn the driven pinion counterclockwise and clockwise several times.

      • If the preload is too high, replace the transfer pinion bearing spacer with a new one.

      • If the preload is too low, tighten the gear nut further by turning it 5 to 10 degrees at a time, and then measure the preload again. Repeat this operation until the specified preload is obtained.

      • If the preload remains too low even after the gear nut has been tightened to a level in excess of the specified torque, loosen the gear nut and check its threads and those of the driven pinion for damage.

      • If there is no damage, replace the transfer pinion bearing spacer with a new one. Apply hypoid gear oil to the threads and repeat the steps above.

      • Write down the preload for use as a reference during the total preload measurement.

    2. Using SST and a torque wrench, measure the total preload.

      SST
      09326-20011
      Preload (at Starting)
      Item Preload
      without SST 0.35 to 0.53 N*m (4 to 5 kgf*cm, 3 to 4 in.*lbf) + driven pinion preload
      with SST 0.25 to 0.38 N*m (3 to 4 kgf*cm, 3 to 3.3 in.*lbf) + driven pinion preload

      Tech Tips


      • Use a torque wrench with a fulcrum length of 130 mm (5.12 in.).

      • Turn the driven pinion counterclockwise and clockwise several times.

      A01ELHOE02

      If the preload is outside the specified range, replace the No. 2 transfer ring gear mounting case washer with one that is thicker or thinner as necessary and recheck.

      Washer Thickness: mm (in.)
      Mark Thickness Mark Thickness
      G7 2.47 (0.0972) M7 3.47 (0.1366)
      G8 2.49 (0.0980) M8 3.49 (0.1374)
      G9 2.51 (0.0988) M9 3.51 (0.1382)
      H0 2.53 (0.0996) N0 3.53 (0.1390)
      H1 2.55 (0.1004) N1 3.55 (0.1398)
      H2 2.57 (0.1012) N2 3.57 (0.1406)
      H3 2.59 (0.1020) N3 3.59 (0.1413)
      H4 2.61 (0.1028) N4 3.61 (0.1421)
      H5 2.63 (0.1035) N5 3.63 (0.1429)
      H6 2.65 (0.1043) N6 3.65 (0.1437)
      H7 2.67 (0.1051) N7 3.67 (0.1445)
      H8 2.69 (0.1059) N8 3.69 (0.1453)
      H9 2.71 (0.1067) N9 3.71 (0.1461)
      J0 2.73 (0.1075) P0 3.73 (0.1469)
      J1 2.75 (0.1083) P1 3.75 (0.1476)
      J2 2.77 (0.1091) P2 3.77 (0.1484)
      J3 2.79 (0.1098) P3 3.79 (0.1492)
      J4 2.81 (0.1106) P4 3.81 (0.1500)
      J5 2.83 (0.1114) P5 3.83 (0.1508)
      J6 2.85 (0.1122) P6 3.85 (0.1516)
      J7 2.87 (0.1130) P7 3.87 (0.1524)
      J8 2.89 (0.1138) P8 3.89 (0.1531)
      J9 2.91 (0.1146) P9 3.91 (0.1539)
      K0 2.93 (0.1154) Q0 3.93 (0.1547)
      K1 2.95 (0.1161) Q1 3.95 (0.1555)
      K2 2.97 (0.1169) Q2 3.97 (0.1563)
      K3 2.99 (0.1177) Q3 3.99 (0.1571)
      K4 3.01 (0.1185) Q4 4.01 (0.1579)
      K5 3.03 (0.1193) Q5 4.03 (0.1587)
      K6 3.05 (0.1201) Q6 4.05 (0.1594)
      K7 3.07 (0.1209) Q7 4.07 (0.1602)
      K8 3.09 (0.1217) Q8 4.09 (0.1610)
      K9 3.11 (0.1224) Q9 4.11 (0.1618)
      L0 3.13 (0.1232) R0 4.13 (0.1626)
      L1 3.15 (0.1240) R1 4.15 (0.1634)
      L2 3.17 (0.1248) R2 4.17 (0.1642)
      L3 3.19 (0.1256) R3 4.19 (0.1650)
      L4 3.21 (0.1264) R4 4.21 (0.1657)
      L5 3.23 (0.1272) R5 4.23 (0.1665)
      L6 3.25 (0.1280) R6 4.25 (0.1673)
      L7 3.27 (0.1287) R7 4.27 (0.1681)
      L8 3.29 (0.1295) R8 4.29 (0.1689)
      L9 3.31 (0.1303) R9 4.31 (0.1697)
      M0 3.33 (0.1311) S0 4.33 (0.1705)
      M1 3.35 (0.1319) S1 4.35 (0.1713)
      M2 3.37 (0.1327) S2 4.37 (0.1720)
      M3 3.39 (0.1335) S3 4.39 (0.1728)
      M4 3.41 (0.1343) S4 4.41 (0.1736)
      M5 3.43 (0.1350) S5 4.43 (0.1744)
      M6 3.45 (0.1358) S6 4.45 (0.1752)

  15. INSPECT RING GEAR BACKLASH


    1. A01ELNO

      Using a dial indicator, check the backlash of the ring gear.

      Backlash
      0.14 to 0.25 mm (0.00551 to 0.00984 in.)

      If the backlash is not within the specification, adjust the side bearing preload or repair as necessary.

      Note

      Check at least 3 positions on the circumference of the ring gear.

  16. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION


    1. A01ELRJ

      Coat 3 or 4 teeth at 4 different positions on the ring gear with Prussian blue.

    2. Turn the driven pinion to rotate the ring gear 10 times or more clockwise and 10 times or more counterclockwise.

    3. Rotate the ring gear to inspect the tooth pattern.

      A01EIPYE07

    4. If the tooth contact pattern is not correct, select a new transfer output shaft washer that is thicker or thinner as necessary and recheck.

  17. REMOVE TRANSFER CASE FRONT OIL SEAL


    1. A01EK1ME01

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

      SST
      09308-00010

      Note

      Do not damage the transfer case front oil seal contact surface on the transfer case.

  18. REMOVE TRANSFER CASE FRONT OIL SEAL (for RH Side)


    1. A01EK09E01

      Using SST, remove the transfer case front oil seal (for RH side) from the transfer case.

      SST
      09308-00010

      Note

      Do not damage the transfer case front oil seal (for RH side) contact surface on the transfer case.

  19. REMOVE BEARING CAP


    1. A01EM8S

      Remove the 2 bolts and bearing cap.

  20. REMOVE NO. 1 TRANSFER OUTPUT SHAFT SPACER


    1. A01EJAYE02
      Text in Illustration
      *1 Screwdriver
      *2 Piece of Cloth
      *3 No. 1 Transfer Output Shaft Spacer

      Using SST, a screwdriver and a hammer, remove the No. 1 transfer output shaft spacer.

      SST
      09504-22011

      Note

      Do not damage the transfer case.

  21. REMOVE NO. 2 TRANSFER RING GEAR MOUNTING CASE WASHER

  22. REMOVE TRANSFER RING GEAR MOUNTING CASE


    1. A01EIMU

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

  23. REMOVE DRIVEN PINION


    1. A01EMLME01

      Using SST and a hammer, unstake the gear nut.

      SST
      09930-00010

      Tech Tips


      • Use SST with the flat side facing outward.

      • Do not machine the tip of SST with a grinder, etc.

    2. A01ELOME01
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, remove the gear nut.

      SST
      09326-20011
      09556-16030
    3. A01EJWA

      Using a press, press out the driven pinion, transfer driven pinion rear bearing (inner race) and transfer pinion bearing spacer.

      Note


      • Place a piece of cloth under the transfer case to prevent the driven pinion from dropping out of the transfer driven pinion rear bearing (inner race).

      • Use wooden blocks or similar objects under the transfer case to keep it level.

  24. REMOVE TRANSFER DRIVEN PINION FRONT BEARING


    1. A01ELVSE01

      Using SST and a press, press out the front transfer driven pinion bearing (inner race).

      SST
      09950-00020
    2. A01ELMU

      Using a brass bar and a hammer, tap the 2 positions shown in the illustration on the driven pinion front bearing (outer race) to remove it from the transfer case.

  25. REMOVE TRANSFER OUTPUT SHAFT WASHER

  26. REMOVE RING GEAR MOUNTING CASE BEARING


    1. Remove the ring gear mounting case bearing (outer race) from the transfer ring gear mounting case.

    2. A01EIUQE03
      Text in Illustration
      *1 Ring Gear Mounting Case Bearing (Inner Race)
      *a Turn
      *b Hold

      Using SST, remove the ring gear mounting case bearing (inner race) 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   ( 09951-00440 )

      Note

      Use SST (09953-04020) after applying grease to its threads and tip.

    3. A01EK29E03
      Text in Illustration
      *1 Ring Gear Mounting Case Bearing (Inner Race)
      *a Turn
      *b Hold

      Using SST, remove the ring gear mounting case bearing (inner race) 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   ( 09951-00400 )

      Note

      Use SST (09953-04020) after applying grease to its threads and tip.

    4. A01EKR2

      Using a brass bar and a hammer, tap the 2 positions shown in the illustration on the ring gear mounting case bearing (outer race) to remove it from the transfer case.

    5. Remove the ring gear mounting case plate washer.

  27. INSPECT RUNOUT OF RING GEAR


    1. A01EM7W

      Place the transfer ring gear mounting case on the V-blocks.

    2. Using a dial indicator, check the runout of the ring gear.

      Maximum runout
      0.06 mm (0.00236 in.)

      Tech Tips

      If the runout is more than maximum, replace the ring gear with a new one.

  28. REMOVE RING GEAR


    1. A01EKLYE03
      Text in Illustration
      *a Matchmark

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

    2. Remove the 10 bolts.

    3. A01EKN4

      Using a plastic hammer, tap on the ring gear to separate it from the transfer ring gear mounting case.

      Note

      Do not damage the ring gear teeth.

  29. INSPECT TRANSFER RING GEAR MOUNTING CASE


    1. A01ELGI

      Place the transfer ring gear mounting case on the V-blocks.

    2. Using a dial indicator, check the runout of the transfer ring gear mounting case.

      Maximum runout
      0.04 mm (0.00157 in.)

      Tech Tips

      If the runout is more than maximum, replace the transfer ring gear mounting case with a new one.

  30. REMOVE TRANSFER DRIVEN PINION REAR BEARING


    1. A01EMCF

      Using a brass bar and a hammer, tap the 2 positions shown in the illustration on the transfer driven pinion rear bearing (outer race) to remove it from the transfer case.