TRANSFER ASSEMBLY REASSEMBLY

Using SST and a press, press the driven pinion rear bearing (outer race) into the case.

SST

09950-60010   ( 09951-00620 )

09950-70010   ( 09951-07150 )

Text in Illustration

*1	Turn
*2	Hold

Apply gear oil to the inner surface of the transfer case.

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

SST

09506-30012

Install the driven pinion to the transfer case.

Install a new transfer pinion bearing spacer and driven pinion rear bearing (inner race) to the driven pinion.

Using SST, install a new gear nut.

SST

09326-20011

09556-16030

Torque:

Reference without SST

270 to 420 N*m  { 2754 to 4282 kgf*cm, 199 to 308 ft.*lbf }

Reference with SST

255 to 396 N*m  { 2601 to 4038 kgf*cm, 188 to 291 ft.*lbf }

Using SST and a torque wrench, measure the driven pinion preload.

SST

09326-20011

Clean the contact surface of the ring gear and transfer ring gear mounting case.

Text in Illustration

*1

Matchmark

After the moisture on the ring gear has completely evaporated, quickly align the matchmarks and set the ring gear onto the transfer ring gear mounting case.

Using SST and a press, press the ring gear mounting case bearing (inner race) RH into the transfer ring gear mounting case.

SST

09950-60010   ( 09951-00420 )

Using SST and a press, press the ring gear mounting case bearing (inner race) LH into the transfer ring gear mounting case.

SST

09223-00010

09726-40010

Using SST and a press, press the ring gear mounting case bearing (outer race) LH into the transfer case.

SST

09950-60010   ( 09951-00620 )

09950-70010   ( 09951-07200 )

Apply gear oil to the transfer ring gear mounting case.

Align the cutout on the No. 1 transfer output shaft spacer with the transfer case hole to install it as shown in the illustration.

Using a brass bar and a hammer, install the No. 2 transfer ring gear mounting case washer.

Install the bearing cap with the 2 bolts.

Torque:

63 N*m  { 644 kgf*cm, 47 ft.*lbf }

Set a dial indicator perpendicular to a ring gear tooth tip. Secure the driven pinion in place and move the ring gear back and forth to measure the backlash.

Text in Illustration

*1	Ring Gear Mounting Case Plate Washer

If the backlash is outside the specified range, select a ring gear mounting case bearing LH side washer from the table below and install it to meet the specified range.

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

Rotate the ring gear to inspect the tooth contact pattern.

Text in Illustration

*1	Transfer Output Shaft Washer

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

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

SST

09326-20011

If the preload is outside the specified range, replace the No. 2 transfer ring gear mounting case washer with one that is thicker or thinner as necessary and recheck.

Using a chisel and a hammer, stake the gear nut.

Using SST and a hammer, drive a new transfer case front oil seal into the case until it reaches the position shown in the illustration.

SST

09950-60010   ( 09951-00350, 09951-00580, 09952-06010 )

09950-70010   ( 09951-07150 )

Using SST and a hammer, drive a new transfer case front oil seal into the transfer case until it reaches the position shown in the illustration.

SST

09608-10010

09950-70010   ( 09951-07150 )

Using SST and a hammer, drive a new transfer case rear oil seal into the extension housing until it reaches the position shown in the illustration.

SST

09325-20010

Using SST and a press, press in the extension housing dust deflector until it contacts the installation surface as shown in the illustration.

SST

09950-60020   ( 09951-00810 )

09950-70010   ( 09951-07150 )

Using SST and a press, press in the extension housing dust deflector until it contacts the installation surface as shown in the illustration.

SST

09950-60020   ( 09951-00810 )

09950-70010   ( 09951-07150 )

Remove any FIPG material and be careful not to drop oil on the contact surfaces of the transfer extension housing sub-assembly and the transfer case.

Install the transfer extension housing sub-assembly with the 4 bolts to the transfer case.

Torque:

26 N*m  { 260 kgf*cm, 19 ft.*lbf }

Using a plastic hammer, drive the 4 transfer case straight pins into the transfer case at the positions shown in the illustration.

Using SST and a hammer, tap in a new breather plug.

SST

09612-10093   ( 09612-10061 )

Install the breather oil deflector with the bolt.

Torque:

6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

Remove any FIPG material and be careful not to drop oil on the contact surfaces of the transfer case cover sub-assembly and the transfer case.

Install the transfer case cover sub-assembly with the 6 bolts.

Torque:

20 N*m  { 200 kgf*cm, 14 ft.*lbf }

Install the transfer case cover sub-assembly with the new 2 bolts.

Torque:

20 N*m  { 200 kgf*cm, 14 ft.*lbf }

Install a new gasket to the transfer drain plug.

Install a new gasket to the No. 1 transfer case plug.

Install a new gasket to the No. 2 transfer case plug.

Install the 4 new transfer and transaxle setting stud bolts to the transfer case positions shown in the illustration.

Torque:

30 N*m  { 306 kgf*cm, 22 ft.*lbf }