TRANSFER ASSEMBLY REMOVAL

CAUTION / NOTICE / HINT

CAUTION:


  • B003QLO

    To prevent burns, do not touch the engine, exhaust pipe or other high temperature components while the engine is hot.

  • B003MKRC03
    *a Object Exceeding Weight Limit of Transmission Jack

    Be sure to perform this procedure with several people as the transfer assembly is very heavy.

  • Be sure to follow the procedure described in the repair manual, or the transmission jack may suddenly drop or a part may fall.

Note

Change the vehicle to H2 before removing the transfer assembly.

If the vehicle cannot be changed to H2, since the new transfer assembly is set to H2, connect all the connectors to the vehicle side wire harnesses to set the new transfer assembly to the drive state of the vehicle before installing the new transfer assembly.

PROCEDURE


  1. DRAIN TRANSFER OIL

    Click here

  2. REMOVE FRONT PROPELLER SHAFT ASSEMBLY

    Click here

  3. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

    Click here

  4. SUPPORT TRANSMISSION ASSEMBLY


  5. REMOVE NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY


  6. REMOVE REAR ENGINE MOUNTING INSULATOR


  7. DISCONNECT GROUND WIRE


  8. SUPPORT TRANSFER ASSEMBLY


    1. Tilt the transmission assembly until the transfer assembly can be removed.

      Note

      Do not damage the wire harness, pipe or surrounding parts.

    2. B003MUNC01
      *A for AC60F
      *B for RC61F

      Support the transfer assembly with a transmission jack.

      Note

      Secure the transfer assembly to the transmission jack using a belt, etc. to prevent it from falling.

  9. DISCONNECT WIRE HARNESS


    1. B003MYYC01
      *A for AC60F
      *B for RC61F

      for AC60F:

      Disconnect the connector and detach the 3 clamps.

    2. for RC61F:

      Disconnect the connector and detach the 2 clamps.

  10. DISCONNECT TRANSFER BREATHER HOSE SUB-ASSEMBLY


    1. B003KKKC01
      *A for AC60F
      *B for RC61F

      Disconnect the 2 transfer breather hose sub-assemblies and detach the 2 clamps.

  11. REMOVE TRANSFER ASSEMBLY


    1. B003KCHC01
      *1 Clamp

      for AC60F:

      Remove the 8 bolts and 2 clamps.

    2. B003QD1C01
      *1 Clamp

      for RC61F:

      Remove the 8 bolts and clamp.

    3. Remove the transfer assembly from the transmission assembly.

      Note

      Do not damage the lip of the transfer adaptor oil seal.

  12. REMOVE TRANSFER CASE LOWER PROTECTOR


    1. B003KAE

      Remove the 4 bolts and transfer case lower protector.