TRANSFER CASE OIL SEAL REPLACEMENT


  1. DRAIN TRANSFER OIL

  2. REMOVE LOWER TRANSFER CASE PROTECTOR


    1. A01J4OU

      Remove the 4 bolts and protector.

  3. REMOVE FRONT PROPELLER SHAFT ASSEMBLY


    1. Remove the front propeller shaft Click here.

  4. REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY


    1. Using a chisel and hammer, loosen the staked part of the lock nut.

    2. A01J4O4E01

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

      SST
      09330-00021
    3. A01J32RE01

      Using SST, remove the companion flange.

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

  5. REMOVE TRANSFER CASE OIL SEAL


    1. A01J7GAE01

      Using SST, tap out the oil seal.

      SST
      09308-00010

      Note

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

  6. INSTALL TRANSFER CASE OIL SEAL


    1. Coat the lip of a new oil seal with MP grease.

    2. A01J73ZE01

      Using SST and a hammer, tap in the oil seal until its surface is flush with the case upper surface.

      SST
      09316-60011   ( 09316-00011 )

  7. INSTALL OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY

    A01J60RE02

    1. Apply gear oil to the connecting areas of the companion flange and driven sprocket.

    2. Install the companion flange to the driven sprocket.

    3. Using SST to hold the companion flange, install a new lock nut.

      SST
      09330-00021
      09950-40011   ( 09951-04020, 09952-04010, 09953-04030, 09955-04051, 09957-04010, 09958-04011 )
      Torque:
      118 N*m  { 1,203 kgf*cm, 87 ft.*lbf }
    4. A01J3WKE01

      Using a chisel and hammer, stake the lock nut to the driven sprocket.

      Note


      • Thoroughly stake the shaft to the lock nut's groove.

      • Be careful not to damage parts around the lock nut.

      • Do not apply excessive force to the shaft.

  8. INSTALL FRONT PROPELLER SHAFT ASSEMBLY


    1. Install the front propeller shaft Click here.

  9. INSTALL LOWER TRANSFER CASE PROTECTOR


    1. A01J4OU

      Install the protector with the 4 bolts.

      Torque:
      18 N*m  { 183 kgf*cm, 13 ft.*lbf }

  10. ADD TRANSFER OIL


    1. Remove the case plug (for filler) and gasket.

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

      Note


      • When adding oil, pour it 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. Install a new gasket and the case plug (for filler).

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