TRANSFER CASE FRONT OIL SEAL REPLACEMENT


  1. DRAIN TRANSFER OIL


    1. A01ERO9

      Remove the 2 bolts and transfer dynamic damper.

    2. A01EO9X

      Remove the 4 bolts and transfer heat insulator.

    3. A01EP6D

      Remove the 7 bolts and lower transfer case protector.

    4. A01ERXS

      Remove the filler plug and gasket.

    5. A01ER8A

      Remove the drain plug and gasket, and drain the transfer oil.

  2. REMOVE FRONT PROPELLER SHAFT ASSEMBLY

    Click here

  3. REMOVE FRONT OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY


    1. A01EMWDE01

      Using SST and a hammer, release the staked part of the nut.

      SST
      09930-00010   ( 09931-00010, 09931-00020 )

      Note


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

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

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

      • Do not damage the threads of the transfer driven sprocket.

    2. A01ERUYE01

      Using SST to hold the companion flange, remove the lock nut.

      SST
      09330-00021
    3. A01ENRPE01

      Using SST, remove the companion flange.

      SST
      09950-40011   ( 09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04051, 09957-04010, 09958-04011 )

    4. Remove the O-ring from the companion flange.

  4. REMOVE FRONT TRANSFER CASE OIL SEAL


    1. A01EPWKE01

      Using SST, remove the front transfer case oil seal.

      SST
      09308-10010
      09950-40011   ( 09957-04010 )

      Note


      • Be careful not to damage the front transfer case oil seal and front transfer case contact surface.

      • Apply grease to the tip of SST center bolt before use.

  5. INSTALL FRONT TRANSFER CASE OIL SEAL


    1. Apply transfer oil to the spline of the driven sprocket.

    2. A01EQSVE01

      Using SST and a hammer, tap in a new front transfer case oil seal.

      SST
      09613-26010

      Note

      The front transfer case oil seal should be installed completely.

  6. INSTALL FRONT OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY


    1. Install the companion flange onto the drive sprocket.

    2. A01ERUYE01

      Using SST to hold the companion flange, install a new O-ring and companion flange lock nut.

      SST
      09330-00021
      Torque:
      127 N*m  { 1299 kgf*cm, 94 ft.*lbf }
    3. A01ERE9E01

      Using a chisel and hammer, stake the companion flange lock nut.

  7. INSTALL FRONT PROPELLER SHAFT ASSEMBLY

    Click here

  8. ADD TRANSFER OIL


    1. A01ER8A

      Install a new gasket to the drain plug and then install the plug.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }
    2. A01ER2OE08

      Add oil so that the oil level is between 0 to 5.0 mm (0 to 0.197 in.) from the bottom lip of the filler plug hole.

      Note


      • Add oil slowly.

      • Add oil a little at a time, waiting several minutes between each addition of oil.

    3. Wait approximately 5 minutes and check that the oil level has not changed.

    4. A01ERXS

      Install a new gasket to the filler plug and then install the plug.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }
    5. A01EP6D

      Install the lower transfer case protector with the 7 bolts.

      Torque:
      14 N*m  { 139 kgf*cm, 10 ft.*lbf }
    6. A01EO9X

      Install the transfer heat insulator with the 4 bolts.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }
    7. A01ERO9

      Install the transfer dynamic damper with the 2 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  9. CHECK FOR TRANSFER OIL LEAK