TRANSFER ASSEMBLY DISASSEMBLY


  1. REMOVE TRANSFER AND TRANSAXLE SETTING STUD BOLT


    1. A019MTF

      Remove the 4 transfer and transaxle setting stud bolts.

  2. REMOVE NO. 2 TRANSFER CASE PLUG


    1. A019M8H

      Remove the No. 2 transfer case plug.

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

  3. REMOVE NO. 1 TRANSFER CASE PLUG


    1. A019JV1

      Remove the No. 1 transfer case plug.

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

  4. REMOVE TRANSFER DRAIN PLUG


    1. A019PMC

      Remove the transfer drain plug.

    2. Remove the gasket from the transfer drain plug.

  5. REMOVE TRANSFER CASE BREATHER PLUG


    1. A019MZD

      Using a screwdriver, remove the transfer case breather plug.

  6. REMOVE TRANSFER CASE COVER SUB-ASSEMBLY


    1. A019NINE01

      Remove the 8 bolts.

    2. A019KET

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

      Note

      Place the brass bar on the rib protruding from the case.

  7. REMOVE BREATHER OIL DEFLECTOR


    1. A019LKJ

      Remove the bolt and breather oil deflector.

  8. REMOVE TRANSFER CASE STRAIGHT PIN


    1. Remove the 4 transfer case straight pins from the transfer case.

      A019LRPE01

  9. SECURE TRANSFER ASSEMBLY


    1. Attach the transfer assembly to the overhaul attachment.

  10. REMOVE TRANSFER EXTENSION HOUSING DUST DEFLECTOR (w/ Heat Insulator)


    1. A019OSV

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

  11. REMOVE TRANSFER EXTENSION HOUSING DUST DEFLECTOR (w/o Heat Insulator)


    1. A019MHM

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

  12. REMOVE TRANSFER CASE REAR OIL SEAL


    1. A019NJ5E01

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

      SST
      09308-00010

      Note

      Be careful not to damage the oil seal contact surface or the inside surface of the oil seal.

  13. REMOVE TRANSFER EXTENSION HOUSING SUB-ASSEMBLY


    1. A019OVI

      Remove the 4 bolts.

    2. A019O5Z

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

  14. INSPECT PRELOAD


    1. A019O4PE01

      Using SST and a torque wrench, measure the preload of the backlash between the driven pinion and ring gear.

      SST
      09326-20011
      Preload (at Starting)
      Item Preload
      without SST 0.5 to 0.9 N*m (5 to 9 kgf*cm, 4 to 8 in.*lbf)
      with SST 0.3 to 0.6 N*m (3 to 6 kgf*cm, 3 to 5 in.*lbf)

      Note


      • The "with SST" torque value is effective when using SST with a fulcrum length of 50 mm (1.97 in.).

      • The "with SST" torque value is effective when using a torque wrench with a fulcrum length of 130 mm (5.12 in.) Click here.

      • The "with SST" torque value is effective when SST is parallel to the torque wrench.

    2. Using SST and a torque wrench, measure the total preload.

      SST
      09326-20011
      Preload (at Starting)
      Item Preload
      without SST 0.4 to 0.5 N*m (4 to 5 kgf*cm, 3 to 4 in.*lbf) + driven pinion preload
      with SST 0.25 to 0.38 N*m (2.6 to 3.8 kgf*cm, 2.3 to 3.3 in.*lbf) + driven pinion preload

      Note


      • The "with SST" torque value is effective when using SST with a fulcrum length of 50 mm (1.97 in.).

      • The "with SST" torque value is effective when using a torque wrench with a fulcrum length of 130 mm (5.12 in.) Click here.

      • The "with SST" torque value is effective when SST is parallel to the torque wrench.

  15. INSPECT RING GEAR BACKLASH


    1. A019M7H

      Using a dial indicator, check the backlash of the ring gear.

      Backlash
      0.14 to 0.25 mm (0.00551 to 0.00984 in.)

      If the backlash is not within the specification, adjust the side bearing preload or repair as necessary.

      Note

      Check at least 3 positions on the circumference of the ring gear.

  16. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVEN PINION


    1. A019MKT

      Coat 3 or 4 teeth at 4 different positions on the ring gear with Prussian blue.

    2. Rotate the ring gear 10 times or more.

    3. Rotate the ring gear to inspect the tooth contact pattern.

      A019PM9E07

    4. If the tooth contact pattern is not correct, select a new transfer output shaft washer that is thicker or thinner as necessary and recheck.

  17. REMOVE TRANSFER CASE FRONT OIL SEAL


    1. A019LGIE01

      Using SST, remove the transfer case front oil seal from the transfer case.

      SST
      09308-00010

      Note

      Do not damage the oil seal contact surface on the case.

  18. REMOVE TRANSFER CASE FRONT OIL SEAL (for RH Side)


    1. A019K0JE01

      Using SST, remove the transfer case front oil seal from the transfer case.

      SST
      09308-00010

      Note

      Do not damage the oil seal contact surface on the case.

  19. REMOVE BEARING CAP


    1. A019KEY

      Remove the 2 bolts and bearing cap.

  20. REMOVE NO. 1 TRANSFER OUTPUT SHAFT SPACER


    1. A019LHCE02
      Text in Illustration
      *1 Screwdriver
      *2 Piece of Cloth
      *3 Spacer

      Using SST, a screwdriver and a hammer, remove the No. 1 transfer output shaft spacer.

      SST
      09504-22011

      Note

      Do not damage the transfer case.

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

  22. REMOVE TRANSFER RING GEAR MOUNTING CASE


    1. A019JVE

      Remove the transfer ring gear mounting case from the transfer case.

  23. REMOVE DRIVEN PINION


    1. A019LHKE01

      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. A019KO0E02
      Text in Illustration
      *1 Turn
      *2 Hold

      Using SST, remove the gear nut.

      SST
      09326-20011
      09556-16030
    3. A019KDH

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

      Note


      • Place a piece of cloth under the transfer case to prevent the driven pinion from dropping out of the bearing.

      • Use wooden blocks or similar objects under the case to keep it level.

  24. REMOVE TRANSFER DRIVEN PINION FRONT BEARING


    1. A019P5BE01

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

      SST
      09950-00020
    2. A019MYO

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

  25. REMOVE TRANSFER OUTPUT SHAFT WASHER


    1. Remove the transfer output shaft washer.

  26. REMOVE RING GEAR MOUNTING CASE BEARING


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

    2. A019KU5E02
      Text in Illustration
      *1 Turn
      *2 Hold

      Using SST, remove the ring gear mounting case bearing (inner race) RH 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.

    3. A019MB6E02
      Text in Illustration
      *1 Turn
      *2 Hold

      Using SST, remove the ring gear mounting case bearing (inner race) LH 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.

    4. A019MB5

      Using a brass bar and a hammer, tap the 2 positions shown in the illustration on the ring gear mounting case bearing (outer race) LH to remove it from the transfer case.

    5. Remove the ring gear mounting case plate washer.

  27. INSPECT RUNOUT OF RING GEAR


    1. A019MWY

      Place the transfer ring gear mounting case on the V-blocks.

    2. Using a dial indicator, check the runout of the ring gear.

      Maximum runout
      0.06 mm (0.00236 in.)

  28. REMOVE RING GEAR


    1. A019JYAE01
      Text in Illustration
      *1 Matchmark

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

    2. Remove the 12 bolts.

    3. A019PKF

      Using a plastic hammer, tap on the ring gear to separate it from the transfer ring gear mounting case.

      Note

      Do not damage the ring gear teeth.

  29. INSPECT TRANSFER RING GEAR MOUNTING CASE


    1. A019K4W

      Place the transfer ring gear mounting case on the V-blocks.

    2. Using a dial indicator, check the runout of the ring gear mounting case.

      Maximum runout
      0.04 mm (0.00157 in.)

  30. REMOVE TRANSFER DRIVEN PINION REAR BEARING


    1. A019KS9

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