TRANSFER ASSEMBLY DISASSEMBLY


  1. REMOVE TRANSFER OIL PAN SUB-ASSEMBLY


    1. A01FE4H

      Remove the 9 bolts.

    2. A01FF55

      Insert the blade of an oil pan seal cutter between the transfer oil pan sub-assembly and transfer case sub-assembly. Cut through the sealer and remove the transfer oil pan sub-assembly.

      Note

      Do not damage the contact surface of the transfer oil pan sub-assembly.

    3. Remove the transfer oil cleaner magnet from the transfer oil pan sub-assembly.

      Note


      • Clean the inside of the transfer oil pan sub-assembly thoroughly, removing all metal shavings, sludge and any other foreign objects.

      • Remove any metal shavings from the transfer oil cleaner magnet.

  2. REMOVE TRANSFER CONTROL VALVE BODY ASSEMBLY


    1. Remove the 4 bolts and the transfer control valve body assembly.

    2. A01FDO3E02
      Text in Illustration
      *1 Connector

      Disconnect the connector from the transfer control solenoid assembly.

    3. A01FISQ

      Remove the bolt and the transfer transmission wire.

  3. REMOVE TRANSFER EXTENSION HOUSING DUST DEFLECTOR


    1. A01FF6OE03
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, remove the transfer extension housing dust deflector.

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

      Note

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

  4. REMOVE TRANSFER CASE SUB-ASSEMBLY


    1. A01FGDPE01
      Text in Illustration
      *1 Clamp

      Remove the 8 bolts and clamp.

    2. A01FGW4

      Using a plastic-faced hammer, tap the transfer case sub-assembly to remove it.

    3. A01FGFLE01
      Text in Illustration
      *1 Clamp

      Remove the bolt and clamp.

  5. REMOVE TRANSFER REAR OUTPUT SHAFT ASSEMBLY


    1. A01FGV2

      Remove the transfer rear output shaft assembly.

  6. REMOVE FLANGE YOKE ASSEMBLY


    1. A01FIECE02

      Using SST and a hammer, release the staked part of the flange yoke 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, etc.

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

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

    2. A01FH0GE04
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, hold the flange yoke assembly.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021

    3. Using a 30 mm deep socket wrench, remove the flange yoke nut.

    4. Remove the flange yoke assembly.

  7. REMOVE TRANSFER REAR CHAIN CASE ASSEMBLY


    1. A01FDKZ

      Remove the 10 bolts.

    2. A01FHQ6

      Tap the 3 protrusions of the transfer rear chain case assembly gently with a brass bar and hammer to loosen, and remove it.

      Note

      Do not damage the transfer rear chain case assembly.

  8. REMOVE TRANSFER FRONT DRIVE CHAIN, TRANSFER DRIVE SPROCKET SUB-ASSEMBLY AND TRANSFER FRONT DRIVE CLUTCH SLEEVE SUB-ASSEMBLY


    1. A01FICU

      Remove the transfer front drive chain, transfer drive sprocket sub-assembly and transfer front drive clutch sleeve sub-assembly.

    2. Remove the transfer front drive chain from the transfer drive sprocket sub-assembly and transfer front drive clutch sleeve sub-assembly.

  9. REMOVE TRANSFER FRONT CHAIN CASE


    1. A01FE00

      Remove the 6 bolts and transfer front chain case.

      Tech Tips

      If necessary, tap the transfer front chain case with a plastic-faced hammer to loosen and remove it.

  10. REMOVE TRANSFER CASE OIL SEAL


    1. A01FH2KE03
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver with its tip taped, pry out the transfer case oil seal from the transfer case sub-assembly.

  11. REMOVE TRANSFER CASE BEARING


    1. A01FE2UE01

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

      SST
      09308-00010

  12. REMOVE TRANSFER BAFFLE VALVE SUB-ASSEMBLY


    1. A01FDFI

      Remove the bolt and transfer baffle valve sub-assembly from the transfer rear chain case assembly.

  13. REMOVE TRANSFER CHAIN CASE GOVERNOR APPLY GASKET


    1. A01FFBYE03
      Text in Illustration
      *A for Front Side
      *B for Rear Side
      *1 Transfer Chain Case Governor Apply Gasket
      *2 O-ring
      *3 Screw

      Remove the screw, O-ring, and 2 transfer chain case governor apply gaskets from the transfer front chain case.

    2. A01FDLG

      Remove the 2 transfer chain case governor apply gaskets from the transfer rear chain case assembly.

  14. REMOVE TRANSFER CHAIN CASE OIL SEAL


    1. A01FG3HE03
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver with its tip taped, pry out the transfer chain case oil seal from the transfer front chain case.

  15. REMOVE TRANSFER REAR OUTPUT SHAFT ASSEMBLY AND CENTER DIFFERENTIAL CARRIER ASSEMBLY


    1. A01FG5DE03
      Text in Illustration
      *1 Transfer Rear Output Shaft Assembly
      *2 Center Differential Carrier Assembly
      *3 Transfer Direct Clutch Drum Sub-assembly

      Remove the transfer rear output shaft assembly and center differential carrier assembly from the transfer direct clutch drum sub-assembly.

  16. REMOVE TRANSFER REAR OUTPUT SHAFT BEARING


    1. A01FIKT

      Remove the transfer rear output shaft bearing from the center differential carrier assembly.

  17. REMOVE CENTER DIFFERENTIAL CLUTCH DISC SET


    1. A01FHCIE03
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver with its tip taped, remove the transfer direct clutch flange snap ring from the transfer direct clutch drum sub-assembly.

    2. A01FE61E02
      Text in Illustration
      *1 Center differential clutch disc flange (No. 1)
      *2 Center differential clutch disc set (Discs)
      *3 Center differential clutch disc set (Plates)
      *4 Center differential clutch disc flange (No. 2)

      Remove the 2 center differential clutch disc flanges and center differential clutch disc set from the transfer direct clutch drum sub-assembly.

  18. REMOVE CENTER DIFFERENTIAL CLUTCH PRESSURE BALANCER


    1. A01FGSIE03
      Text in Illustration
      *1 Transfer Direct Clutch Return Spring Snap Ring

      Place SST on the center differential clutch pressure balancer and compress the transfer direct clutch return spring assembly with a press.

      SST
      09350-30020   ( 09350-07040 )

    2. Using SST, remove the transfer direct clutch return spring snap ring.

      SST
      09350-30020   ( 09350-07040, 09350-07070 )
    3. A01FF3G

      Remove the center differential clutch pressure balancer from the transfer direct clutch drum sub-assembly.

  19. REMOVE TRANSFER DIRECT CLUTCH RETURN SPRING ASSEMBLY


    1. A01FFVG

      Remove the transfer direct clutch return spring assembly from the transfer direct clutch drum sub-assembly.

  20. REMOVE CENTER DIFFERENTIAL CLUTCH PISTON


    1. A01FJ0ZE03
      Text in Illustration
      *1 Transfer Direct Clutch Drum Sub-assembly
      *2 Transfer Center Support Assembly

      Install the transfer direct clutch drum sub-assembly to the transfer center support assembly.

    2. A01FFO5E03
      Text in Illustration
      *1 Center Differential Clutch Piston
      *a Oil Hole

      While pushing down evenly on the center differential clutch piston, apply air (200 kPa, 2.0 kgf/cm2, 19 psi) at the oil hole on the transfer rear chain case assembly as shown in the illustration to remove the center differential clutch piston from the transfer direct clutch drum sub-assembly.

    3. Remove the transfer direct clutch drum sub-assembly from the transfer center support assembly.

  21. REMOVE TRANSFER DIRECT CLUTCH PISTON O-RING


    1. A01FIDXE03
      Text in Illustration
      *1 Transfer Direct Clutch Piston O-ring

      Remove the 2 transfer direct clutch piston O-rings from the center differential clutch piston.

  22. REMOVE TRANSFER CENTER SUPPORT ASSEMBLY


    1. A01FGCS

      Remove the 5 bolts and transfer center support assembly.

    2. Remove the 2 screws and 2 O-rings from the transfer rear chain case assembly.

  23. REMOVE TRANSFER CENTER SUPPORT SEAL RING


    1. A01FJ4JE03
      Text in Illustration
      *1 Transfer Center Support Seal Ring

      Remove the 2 transfer center support seal rings from the transfer center support assembly.

  24. REMOVE TRANSFER DRIVEN SPROCKET BEARING


    1. A01FE3XE01
      Text in Illustration
      *1 Transfer Driven Sprocket Bearing

      Using SST and a press, remove the transfer driven sprocket bearing from the transfer front drive clutch sleeve sub-assembly.

      SST
      09950-00020
    2. A01FG48E01
      Text in Illustration
      *1 Transfer Driven Sprocket Bearing

      Using SST and a press, remove the transfer driven sprocket bearing from the transfer front drive clutch sleeve sub-assembly.

      SST
      09950-00020
      09950-60010   ( 09951-00530 )
      09950-70010   ( 09951-07100 )

  25. REMOVE TRANSFER DRIVE SPROCKET BEARING


    1. A01FJ2IE01
      Text in Illustration
      *1 Transfer Drive Sprocket Bearing

      Using SST and a press, remove the transfer drive sprocket bearing from the transfer drive sprocket sub-assembly.

      SST
      09950-00020
      09950-60010   ( 09951-00480 )
      09950-70010   ( 09951-07100 )
    2. A01FIARE01
      Text in Illustration
      *1 Transfer Drive Sprocket Bearing

      Using SST and a press, remove the transfer drive sprocket bearing from the transfer drive sprocket sub-assembly.

      SST
      09950-00020
      09950-60010   ( 09951-00530 )
      09950-70010   ( 09951-07100 )

  26. REMOVE TRANSFER CONTROL SOLENOID ASSEMBLY


    1. A01FG8KE01
      Text in Illustration
      *1 Transfer Control Solenoid Assembly
      *2 Solenoid Lock Plate

      Remove the bolt, solenoid lock plate and transfer control solenoid assembly.