TRANSFER ASSEMBLY DISASSEMBLY

CAUTION / NOTICE / HINT

Note

Before installation of each part, thoroughly clean and dry it. Then apply grease or oil as necessary. Do not use alkaline chemicals to clean aluminum parts, rubber parts or precoated bolts. Also, do not use non-residue solvent or other cleaning oils to clean O-rings, oil seals or rubber parts.

PROCEDURE


  1. REMOVE TRANSFER AND TRANSAXLE SETTING STUD BOLT


    1. A01V95WC01
      *A for K111F
      *B for U660F, U760F, EA64F, EB61F, EB63F, K114F

      Using 2 nuts, remove the 4 transfer and transaxle setting stud bolts.

  2. SECURE TRANSFER ASSEMBLY

    A01V8E9C01
    *A for K111F
    *B for U660F, U760F, EA64F, EB61F, EB63F, K114F

    1. Secure the transfer assembly to the overhaul attachment.

  3. REMOVE TRANSFER CASE STRAIGHT PIN

    A01VAYBC01
    *A for K111F
    *B for U660F, U760F, EA64F, EB61F, EB63F, K114F

    1. Remove the 2 transfer case straight pins.

  4. REMOVE NO. 1 TRANSFER CASE PLUG

    A01V6RV

    1. Remove the No. 1 transfer case plug and gasket.

  5. REMOVE TRANSFER DRAIN PLUG

    A01V9B4C01
    *A for K111F
    *B for U660F, U760F, EA64F, EB61F, EB63F, K114F

    1. Using a 10 mm socket hexagon wrench, remove the transfer drain plug and gasket.

  6. REMOVE NO. 2 TRANSFER CASE PLUG

    A01V9OXC01
    *A for K111F
    *B for U660F, U760F, EA64F, EB61F, EB63F, K114F

    1. Using a 10 mm socket hexagon wrench, remove the No. 2 transfer case plug (filler plug) and gasket.

  7. REMOVE TRANSFER CASE BREATHER PLUG

    A01V81S

    1. Using a chisel and hammer, slightly pry out the transfer case breather plug.

    2. Using a screwdriver, lightly pry up and remove the transfer case breather plug.

  8. REMOVE TRANSFER CASE OIL SEAL

    A01V8AGC01
    *A for K111F
    *B for U660F, U760F, EA64F, EB61F, EB63F, K114F
    *1 Transfer Case Oil Seal

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

      SST
      09308-00010

      Note

      Do not scratch the press-fitting surface of the transfer case oil seal.

  9. REMOVE TRANSFER CASE OIL SEAL RH

    A01V8T2C03
    *1 Transfer Case Oil Seal RH

    1. Using SST, remove the transfer case oil seal RH from the No. 1 transfer case cover.

      SST
      09308-00010

      Note

      Do not scratch the press-fitting surface of the transfer case oil seal RH.

  10. INSPECT TOTAL PRELOAD

    A01VAQRC02
    *1 Nut

    1. Install nuts to the stud bolts.

      Tech Tips

      Use nuts that are used for installing the propeller shaft.

    2. Using a torque wrench, check the total preload (starting torque) with the teeth of the drive pinion and ring gear in contact.

      Torque:
      Total preload (starting torque)
      0.87 N*m  { 8.88 kgf*cm, 29.06 kgf*cm, 7.71 in.*lbf, 25.22 in.*lbf }

      Tech Tips

      Install the torque wrench as shown in the illustration.

  11. INSPECT RING GEAR BACKLASH

    A01VA4C

    1. Insert a dial indicator through the No. 2 transfer case plug hole, and set it perpendicular to the edge of a ring gear tooth.

      If the backlash is not within the specified range, adjust the backlash or repair as necessary.

    2. While securing the transfer output shaft by hand, rotate the transfer ring gear mounting case forward and backward by hand and measure the backlash of the ring gear and driven pinion.

      Standard backlash
      0.10 to 0.20 mm (0.00394 to 0.00787 in.)

      Note

      Measure the ring gear at 3 or more locations.

  12. REMOVE NO. 1 TRANSFER CASE COVER


    1. A01V7EO

      Remove the 8 bolts.

    2. A01V917

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

      Note


      • Put the brass bar against the rib of the No. 1 transfer case cover.

      • When removing the No. 1 transfer case cover, be careful not to scratch the installation surface.

      Tech Tips

      To prevent the No. 1 transfer case cover from falling, leave 2 of the bolts screwed in by 5 or 6 threads.

  13. REMOVE TRANSFER RING GEAR

    A01V9GI

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

  14. REMOVE TRANSFER CASE STRAIGHT PIN

    A01VAUM

    1. Remove the 2 transfer case straight pins from the transfer case.

  15. INSPECT DRIVEN PINION PRELOAD


    1. A01V9XMC02
      *1 Nut

      Install nuts to the stud bolts.

      Tech Tips

      Use nuts that are used for installing the propeller shaft.

    2. Using a torque wrench, check the driven pinion preload (starting torque) of the driven pinion.

      Torque:
      Driven pinion preload (starting torque)
      0.39 N*m  { 3.98 kgf*cm, 22.53 kgf*cm, 3.46 in.*lbf, 19.55 in.*lbf }

      Tech Tips

      Install the torque wrench as shown in the illustration.

  16. REMOVE REAR TRANSFER OUTPUT SHAFT SUB-ASSEMBLY

    A01VAH8

    1. Remove the 5 bolts and rear transfer output shaft sub-assembly from the transfer case.

    2. Mount the rear transfer output shaft sub-assembly in a vise between aluminum plates.

      Note

      Do not overtighten the vise.

    3. A01V89EN07

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

      SST
      09930-00010

      Note


      • Be sure to use SST with the tapered surface facing the shaft.

      • Do not grind the tip of SST with a grinder or other device.

      • Completely loosen the staked part of the transfer gear nut when removing it.

      • Do not damage the threads of the output shaft sub-assembly.

    4. Using a 30 mm socket wrench, remove the transfer gear nut.

  17. REMOVE TRANSFER DRIVEN PINION


    1. A01V9KSN10

      Using SST and a press, remove the transfer driven pinion from the rear transfer output shaft sub-assembly.

      SST
      09950-00020
      09950-60010   ( 09951-00240 )
      09950-70010   ( 09951-07100 )

      Note

      Support the front transfer driven pinion bearing as shown in the illustration to avoid placing stress on the outer race.

  18. REMOVE REAR TRANSFER OUTPUT SHAFT DUST DEFLECTOR


    1. A01V7OKN10

      Using SST and a press, remove the rear transfer output shaft dust deflector from the rear transfer output shaft sub-assembly.

      SST
      09950-00020

  19. REMOVE FRONT TRANSFER DRIVEN PINION BEARING

    A01V7YUN10

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

      SST
      09950-00020
      09950-60010   ( 09951-00410 )
      09950-70010   ( 09951-07100 )

      Note

      Support the front transfer driven pinion bearing as shown in the illustration to avoid placing stress on the outer race.

    2. A01V8I7

      Remove the O-ring from the front transfer driven pinion bearing.

  20. REMOVE TRANSFER OUTPUT SHAFT WASHER

    A01V773

    1. Remove the transfer output shaft washer from the transfer driven pinion.

  21. REMOVE RING GEAR MOUNTING CASE BEARING RH

    A01V9VUC02
    *a Turn
    *b Hold

    1. Using SST, remove the ring gear mounting case bearing RH (inner race) from the transfer ring gear mounting case.

      SST
      09950-40011   ( 09951-04010, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011 )
      09950-60010   ( 09951-00540 )

      Note


      • Apply a lubricant to the threads and end of SST.

      • Do not deform the cage of the ring gear mounting case bearing RH (inner race) (when reusing the bearing).

      • Place identification marks on the left and right ring gear mounting case bearings to distinguish them (backside, teeth side). Then store them separately (when reusing the bearings).

    2. A01VAW7C03
      *1 No. 2 Transfer Ring Gear Mounting Case Washer
      *2 Ring Gear Mounting Case Bearing RH (Outer Race)

      Using SST and a hammer, remove the No. 2 transfer ring gear mounting case washer and ring gear mounting case bearing RH (outer race) from the No. 1 transfer case cover.

      SST
      09310-35010

  22. REMOVE RING GEAR MOUNTING CASE BEARING LH

    A01V82OC02
    *a Turn
    *b Hold

    1. Using SST, remove the ring gear mounting case bearing LH (inner race) from the transfer ring gear mounting case.

      SST
      09950-00020
      09950-00030

      Note


      • Apply a lubricant to the threads and end of SST.

      • Do not deform the cage of the ring gear mounting case bearing LH (inner race) (when reusing the bearing).

      • Place identification marks on the left and right ring gear mounting case bearings to distinguish them (backside, teeth side). Then store them separately (when reusing the bearings).

    2. A01V76GC01
      *A for K111F
      *B for U660F, U760F, EA64F, EB61F, EB63F, K114F
      *1 No. 1 Ring Gear Mounting Case Washer
      *2 Ring Gear Mounting Case Bearing LH (Outer Race)

      Using SST and a hammer, remove the No. 1 ring gear mounting case washer and ring gear mounting case bearing LH (outer race) from the transfer case.

      SST
      09636-20010

  23. REMOVE SHAFT SNAP RING

    A01VAAV

    1. Using a snap ring expander, remove the shaft snap ring.

  24. REMOVE TRANSFER RING GEAR MOUNTING CASE

    A01V9VZN10

    1. Using SST and a press, remove the transfer ring gear mounting case from the transfer ring gear.

      SST
      09950-60010   ( 09951-00400 )

  25. REMOVE BREATHER OIL DEFLECTOR

    A01V7GZC01
    *A for K111F
    *B for U660F, U760F, EA64F, EB61F, EB63F, K114F

    1. Remove the 2 bolts and breather oil deflector from the transfer case.