TRANSFER ASSEMBLY DISASSEMBLY

CAUTION / NOTICE / HINT

Note:

Before installation of each part, thoroughly clean and dry it. Then apply grease or oil as necessary. Do not use alkaline chemicals to clean aluminum parts, rubber parts or precoated bolts. Also, do not use non-residue solvent or other cleaning oils to clean O-rings, oil seals or rubber parts.

PROCEDURE

  1. REMOVE TRANSFER AND TRANSAXLE SETTING STUD BOLT

    1. C277113C01

      *A

      for CVT

      *B

      for Automatic Transaxle and Manual Transaxle

      Using 2 nuts, remove the 4 transfer and transaxle setting stud bolts.

  2. SECURE TRANSFER ASSEMBLY

    C278909C01

    *A

    for CVT

    *B

    for Automatic Transaxle and Manual Transaxle

    1. Secure the transfer assembly to the overhaul attachment.

  3. REMOVE TRANSFER CASE STRAIGHT PIN

    C278910C01

    *A

    for CVT

    *B

    for Automatic Transaxle and Manual Transaxle

    1. Remove the 2 transfer case straight pins.

  4. REMOVE NO. 1 TRANSFER CASE PLUG

    C130044

    1. Remove the No. 1 transfer case plug and gasket.

  5. REMOVE TRANSFER DRAIN PLUG

    C278911C01

    *A

    for CVT

    *B

    for Automatic Transaxle and Manual Transaxle

    1. Using a 10 mm socket hexagon wrench, remove the transfer drain plug and gasket.

  6. REMOVE NO. 2 TRANSFER CASE PLUG

    C278912C01

    *A

    for CVT

    *B

    for Automatic Transaxle and Manual Transaxle

    1. Using a 10 mm socket hexagon wrench, remove the No. 2 transfer case plug (filler plug) and gasket.

  7. REMOVE TRANSFER CASE BREATHER PLUG

    C222931

    1. Using a chisel and hammer, slightly pry out the transfer case breather plug.

    2. Using a screwdriver, lightly pry up and remove the transfer case breather plug.

  8. REMOVE TRANSFER CASE OIL SEAL

    C278959C01

    *A

    for CVT

    *B

    for Automatic Transaxle and Manual Transaxle

    *1

    Transfer Case Oil Seal

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

      09308-00010

      Note:

      Do not scratch the press-fitting surface of the transfer case oil seal.

  9. REMOVE TRANSFER CASE OIL SEAL RH

    C130055C03

    *1

    Transfer Case Oil Seal RH

    1. Using SST, remove the transfer case oil seal RH from the No. 1 transfer case cover.

      09308-00010

      Note:

      Do not scratch the press-fitting surface of the transfer case oil seal RH.

  10. INSPECT TOTAL PRELOAD

    C130167C02

    *1

    Nut

    1. Install nuts to the stud bolts.

      Tip:

      Use nuts that are used for installing the propeller shaft.

    2. Using a torque wrench, check the total preload (starting torque) with the teeth of the drive pinion and ring gear in contact.

      Total preload (starting torque)

      0.47 N*m

      2.2 N*m

      4.80 kgf*cm

      22.43 kgf*cm

      4.16 in.*lbf

      19.47 in.*lbf

      Tip:

      Install the torque wrench as shown in the illustration.

  11. INSPECT RING GEAR BACKLASH

    C158062

    1. Insert a dial indicator through the No. 2 transfer case plug hole, and set it perpendicular to the edge of a ring gear tooth.

      If the backlash is not within the specified range, adjust the backlash or repair as necessary.

    2. While securing the transfer output shaft by hand, rotate the transfer ring gear mounting case forward and backward by hand and measure the backlash of the ring gear and driven pinion.

      Standard backlash

      0.10 to 0.20 mm (0.00394 to 0.00787 in.)

      Note:

      Measure the ring gear at 3 or more locations.

  12. REMOVE NO. 1 TRANSFER CASE COVER

    1. C130048

      Remove the 8 bolts.

    2. C130049

      Using a brass bar and hammer, remove the No. 1 transfer case cover from the transfer case.

      Note:

      • Put the brass bar against the rib of the No. 1 transfer case cover.

      • When removing the No. 1 transfer case cover, be careful not to scratch the installation surface.

      Tip:

      To prevent the No. 1 transfer case cover from falling, leave 2 of the bolts screwed in by 5 or 6 threads.

  13. REMOVE TRANSFER RING GEAR

    C130050

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

  14. REMOVE TRANSFER CASE STRAIGHT PIN

    C130051

    1. Remove the 2 transfer case straight pins from the transfer case.

  15. INSPECT DRIVEN PINION PRELOAD

    1. C130052C02

      *1

      Nut

      Install nuts to the stud bolts.

      Tip:

      Use nuts that are used for installing the propeller shaft.

    2. Using a torque wrench, check the driven pinion preload (starting torque) of the driven pinion.

      Driven pinion preload (starting torque)

      0.24 N*m

      1.39 N*m

      2.45 kgf*cm

      14.17 kgf*cm

      2.13 in.*lbf

      12.30 in.*lbf

      Tip:

      Install the torque wrench as shown in the illustration.

  16. REMOVE REAR TRANSFER OUTPUT SHAFT SUB-ASSEMBLY

    C130053

    1. Remove the 5 bolts and rear transfer output shaft sub-assembly from the transfer case.

    2. Mount the rear transfer output shaft sub-assembly in a vise between aluminum plates.

      Note:

      Do not overtighten the vise.

    3. C130056N07

      Using SST and a hammer, unstake the transfer gear nut.

      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 or other device.

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

      • Do not damage the threads of the output shaft sub-assembly.

    4. Using a 30 mm socket wrench, remove the transfer gear nut.

  17. REMOVE TRANSFER DRIVEN PINION

    1. C109627N10

      w/o Washer:

      1. Using SST and a press, remove the transfer driven pinion from the rear transfer output shaft sub-assembly.

        09950-00020

        09950-60010

        09951-00240

        09950-70010

        09951-07100

        Note:

        Support the front transfer driven pinion bearing as shown in the illustration to avoid placing stress on the outer race.

    2. C109627N10

      w/ Washer:

      1. Using SST and a press, remove the transfer driven pinion and washer from the rear transfer output shaft sub-assembly.

        09950-00020

        09950-60010

        09951-00240

        09950-70010

        09951-07100

        Note:

        Support the front transfer driven pinion bearing as shown in the illustration to avoid placing stress on the outer race.

  18. REMOVE REAR TRANSFER OUTPUT SHAFT DUST DEFLECTOR

    1. C109629N10

      Using SST and a press, remove the rear transfer output shaft dust deflector from the rear transfer output shaft sub-assembly.

      09950-00020

  19. REMOVE FRONT TRANSFER DRIVEN PINION BEARING

    C109628E02

    1. Using SST and a press, remove the front transfer driven pinion bearing from the transfer driven pinion.

      09950-00020

      09950-60010

      09951-00410

      09950-70010

      09951-07100

      Note:

      Support the front transfer driven pinion bearing as shown in the illustration to avoid placing stress on the outer race.

    2. C109630

      Remove the O-ring from the front transfer driven pinion bearing.

  20. REMOVE TRANSFER OUTPUT SHAFT WASHER

    C110759

    1. Remove the transfer output shaft washer from the transfer driven pinion.

  21. REMOVE RING GEAR MOUNTING CASE BEARING RH

    C269126C02

    *a

    Turn

    *b

    Hold

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

      09950-40011

      09951-04010

      09952-04010

      09953-04030

      09954-04010

      09955-04061

      09957-04010

      09958-04011

      09950-60010

      09951-00540

      Note:

      • Apply a lubricant to the threads and end of SST.

      • Do not deform the cage of the ring gear mounting case bearing RH (inner race) (when reusing the bearing).

      • Place identification marks on the left and right ring gear mounting case bearings to distinguish them (backside, teeth side). Then store them separately (when reusing the bearings).

    2. C156143C03

      *1

      No. 2 Transfer Ring Gear Mounting Case Washer

      *2

      Ring Gear Mounting Case Bearing RH (Outer Race)

      Using SST and a hammer, remove the No. 2 transfer ring gear mounting case washer and ring gear mounting case bearing RH (outer race) from the No. 1 transfer case cover.

      09310-35010

  22. REMOVE RING GEAR MOUNTING CASE BEARING LH

    C269127C02

    *a

    Turn

    *b

    Hold

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

      09950-00020

      09950-00030

      Note:

      • Apply a lubricant to the threads and end of SST.

      • Do not deform the cage of the ring gear mounting case bearing LH (inner race) (when reusing the bearing).

      • Place identification marks on the left and right ring gear mounting case bearings to distinguish them (backside, teeth side). Then store them separately (when reusing the bearings).

    2. C277127C01

      *A

      for CVT

      *B

      for Automatic Transaxle and Manual Transaxle

      *1

      No. 1 Ring Gear Mounting Case Washer

      *2

      Ring Gear Mounting Case Bearing LH (Outer Race)

      Using SST and a hammer, remove the No. 1 ring gear mounting case washer and ring gear mounting case bearing LH (outer race) from the transfer case.

      09636-20010

  23. REMOVE SHAFT SNAP RING

    C109636

    1. Using a snap ring expander, remove the shaft snap ring.

  24. REMOVE TRANSFER RING GEAR MOUNTING CASE

    C109637N10

    1. Using SST and a press, remove the transfer ring gear mounting case from the transfer ring gear.

      09950-60010

      09951-00400

  25. REMOVE BREATHER OIL DEFLECTOR

    C277128C01

    *A

    for CVT

    *B

    for Automatic Transaxle and Manual Transaxle

    1. Remove the 2 bolts and breather oil deflector from the transfer case.