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. A01QVRU

      Remove the 4 transfer and transaxle setting stud bolts from the transfer case sub-assembly.

  2. REMOVE NO. 2 TRANSFER CASE PLUG


    1. A0029MM

      Remove the No. 2 transfer case plug from the transfer case sub-assembly.

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

  3. REMOVE NO. 1 TRANSFER CASE PLUG


    1. A0026YJ

      Remove the No. 1 transfer case plug from the transfer case sub-assembly.

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

  4. REMOVE TRANSFER DRAIN PLUG


    1. A002AJ4

      Remove the transfer drain plug from the transfer case sub-assembly.

    2. Remove the gasket from the transfer drain plug.

  5. REMOVE TRANSFER CASE BREATHER PLUG


    1. A01QUU8

      Using a chisel and hammer, lift the transfer case breather plug slightly.

    2. Using a screwdriver, remove the transfer case breather plug from the transfer case cover sub-assembly.

  6. REMOVE TRANSFER CASE COVER SUB-ASSEMBLY


    1. A01QVYB

      Remove the 8 bolts from the transfer case cover sub-assembly.

    2. A01QWI4C01
      *a Rib
      *b Brass Bar

      Using a brass bar and a hammer, remove the transfer case cover sub-assembly from the transfer case sub-assembly.

      Note

      Place the brass bar on the rib protruding from the transfer case cover sub-assembly.

  7. REMOVE BREATHER OIL DEFLECTOR


    1. A01QVFB

      Remove the bolt and breather oil deflector from the transfer case cover sub-assembly.

  8. REMOVE TRANSFER CASE STRAIGHT PIN


    1. Remove the 4 transfer case straight pins from the transfer case sub-assembly.

      A01QV4D

  9. SECURE TRANSFER ASSEMBLY


    1. Attach the transfer assembly to the overhaul attachment.

  10. REMOVE TRANSFER EXTENSION HOUSING DUST DEFLECTOR


    1. A01QVJ0

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

  11. REMOVE TRANSFER EXTENSION HOUSING TYPE T OIL SEAL


    1. A01QVNUC01
      *1 Transfer Extension Housing Type T Oil Seal

      Using SST, remove the transfer extension housing type T oil seal from the transfer extension housing sub-assembly.

      SST
      09308-00010

      Note

      Be careful not to damage the transfer extension housing type T oil seal contact surface or the inside surface of the transfer extension housing type T oil seal.

  12. REMOVE TRANSFER EXTENSION HOUSING SUB-ASSEMBLY


    1. A01QVT1

      Remove the 4 bolts.

    2. A01QWKO

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

  13. INSPECT PRELOAD

    Click here

  14. INSPECT RING GEAR BACKLASH

    Click here

  15. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVEN PINION

    Click here

  16. REMOVE TRANSFER CASE OIL SEAL


    1. A01QW60C02
      *1 Transfer Case Oil Seal

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

      SST
      09308-00010

      Note

      Do not damage the transfer case oil seal contact surface to the transfer case sub-assembly.

  17. REMOVE TRANSFER CASE OIL SEAL RH


    1. A01QWRNC03
      *1 Transfer Case Oil Seal RH

      Using SST, remove the transfer case oil seal RH from the transfer case sub-assembly.

      SST
      09308-00010

      Note

      Do not damage the transfer case oil seal RH contact surface to the transfer case sub-assembly.

  18. REMOVE BEARING CAP


    1. A002CCB

      Remove the 2 bolts and bearing cap from the transfer case sub-assembly.

  19. REMOVE NO. 1 TRANSFER OUTPUT SHAFT SPACER


    1. A01QV1SC03
      *1 No. 1 Transfer Output Shaft Spacer
      *a Screwdriver
      *b Piece of Cloth

      Using SST, a screwdriver and a hammer, remove the No. 1 transfer output shaft spacer from the transfer case sub-assembly.

      SST
      09504-22012

      Note

      Do not damage the transfer case sub-assembly.

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


    1. Remove the No. 2 transfer ring gear mounting case washer from the transfer case sub-assembly.

  21. REMOVE TRANSFER RING GEAR MOUNTING CASE


    1. A00288A

      Remove the transfer ring gear mounting case from the transfer case sub-assembly.

  22. REMOVE DRIVEN PINION


    1. A01QW9KN02

      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. A01QW2YC01
      *a Turn
      *b Hold

      Using SST, remove the gear nut.

      SST
      09326-20011
    3. A01QW8SC01
      *1 Rear Transfer Driven Pinion Bearing (inner race)
      *2 Transfer Pinion Bearing Spacer
      *3 Driven Pinion

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

      Note


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

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

  23. REMOVE FRONT TRANSFER DRIVEN PINION BEARING


    1. A01QWSPN03

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

      SST
      09950-00020

      Note


      • Make sure to keep the outer race of the front transfer driven pinion bearing (inner race) from being applied force as shown the illustration.

      • Do not deform the cage of the front transfer driven pinion bearing (inner race) (when reusing the front transfer driven pinion bearing (inner race)).

    2. A01QVHR

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

      Note

      Fit the brass bar to the 2 cutouts of the transfer case sub-assembly.

  24. REMOVE TRANSFER OUTPUT SHAFT WASHER


    1. Remove the transfer output shaft washer from the transfer case sub-assembly.

      Note

      If the transfer output shaft washer is damaged or deformed, replace it with a new one.

  25. REMOVE RING GEAR MOUNTING CASE BEARING


    1. for RH side:


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

      2. A01QVLOC01
        *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.

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

        • 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 ring gear mounting case bearings).

    2. for LH side:


      1. A01QVYNC01
        *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.

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

        • 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 ring gear mounting case bearings).

      2. A01QUVZ

        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 sub-assembly.

        Note

        Fit the brass bar to the 2 cutouts of the transfer case sub-assembly.

      3. Remove the ring gear mounting case plate washer from the transfer case sub-assembly.

        Note

        If the ring gear mounting case plate washer is damaged or deformed, replace it with a new one.

  26. INSPECT RUNOUT OF RING GEAR

    Click here

  27. REMOVE RING GEAR


    1. Secure the transfer ring gear mounting case in a vise using aluminum plates.

      Note

      Be careful not to damage the transfer ring gear mounting case in the vise.

    2. A01QVU6C01
      *a Matchmark

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

    3. Remove the 12 bolts.

    4. A01QV10

      Using a plastic hammer, remove the ring gear from the transfer ring gear mounting case.

      Note

      Do not damage the ring gear teeth.

  28. INSPECT TRANSFER RING GEAR MOUNTING CASE

    Click here

  29. REMOVE REAR TRANSFER DRIVEN PINION BEARING (OUTER RACE)


    1. A01QW42

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

      Note

      Fit the brass bar to the 2 cutouts of the transfer case sub-assembly.