DISASSEMBLY
CAUTION / NOTICE / HINT
NOTICE:
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
(a) Using 2 nuts, remove the 4 transfer and transaxle setting stud bolts. | |
2. SECURE TRANSFER ASSEMBLY
(a) Secure the transfer assembly to the overhaul attachment.
3. REMOVE TRANSFER CASE STRAIGHT PIN
(a) Remove the 2 transfer case straight pins.
4. REMOVE NO. 1 TRANSFER CASE PLUG
(a) Remove the No. 1 transfer case plug and gasket.
5. REMOVE TRANSFER DRAIN PLUG
(a) Using a 10 mm socket hexagon wrench, remove the transfer drain plug and gasket.
6. REMOVE TRANSFER FILLER PLUG
(a) Using a 10 mm socket hexagon wrench, remove the transfer filler plug and gasket.
7. REMOVE TRANSFER CASE BREATHER PLUG
(a) Using a chisel and hammer, slightly pry out the transfer case breather plug.
(b) Using a screwdriver, lightly pry up and remove the transfer case breather plug.
8. REMOVE TRANSFER CASE OIL SEAL
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9. REMOVE TRANSFER CASE OIL SEAL RH
*1 | Transfer Case Oil Seal RH |
(a) Using SST, remove the transfer case oil seal RH from the No. 1 transfer case cover.
SST: 09308-00010
NOTICE:
Do not scratch the press-fitting surface of the transfer case oil seal RH.
10. INSPECT TOTAL PRELOAD
*1 | Double Nut |
*a | Torque Wrench Fulcrum Length |
(a) Install the double nut to the transfer output shaft stud bolt and set the torque wrench into place.
HINT:
Adjust the double nut until the torque wrench is straight.
(b) Using a torque wrench, check the total preload (starting torque) with the teeth of the drive pinion and ring gear in contact.
Torque:
Total preload (starting torque) :
0.87-2.85 N·m {8.88-29.06 kgf·cm, 7.71-25.22 in·lbf}
HINT:
T' | Reading of torque wrench (N*m (kgf*cm, ft.*lbf)) |
T | Driven pinion preload (N*m (kgf*cm, ft.*lbf)) |
L1 | Distance from center of transfer output shaft to center of stud bolt (cm (in.)) |
L2 | Length of torque wrench (cm (in.)) |
11. INSPECT RING GEAR BACKLASH
(a) 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.
(b) 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.)
NOTICE:
Measure the ring gear at 3 or more locations.
12. REMOVE NO. 1 TRANSFER CASE COVER
(a) Remove the 8 bolts. | |
(b) Using a brass bar and hammer, remove the No. 1 transfer case cover from the transfer case. NOTICE:
HINT: 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
(a) Remove the transfer ring gear from the transfer case. | |
14. REMOVE TRANSFER CASE STRAIGHT PIN
(a) Remove the 2 transfer case straight pins from the transfer case. | |
15. INSPECT DRIVEN PINION PRELOAD
(a) Install the double nut to the transfer output shaft stud bolt and set the torque wrench into place. HINT: Adjust the double nut until the torque wrench is straight. |
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(b) Using a torque wrench, check the total preload (starting torque) with the teeth of the drive pinion and ring gear in contact.
Torque:
Driven pinion preload (starting torque) :
0.39-2.21 N·m {3.98-22.53 kgf·cm, 3.46-19.55 in·lbf}
HINT:
T' | Reading of torque wrench (N*m (kgf*cm, ft.*lbf)) |
T | Driven pinion preload (N*m (kgf*cm, ft.*lbf)) |
L1 | Distance from center of transfer output shaft to center of stud bolt (cm (in.)) |
L2 | Length of torque wrench (cm (in.)) |
16. REMOVE REAR TRANSFER OUTPUT SHAFT SUB-ASSEMBLY
(a) Remove the 5 bolts and rear transfer output shaft sub-assembly from the transfer case. | |
(b) Mount the rear transfer output shaft sub-assembly in a vise between aluminum plates.
NOTICE:
Do not overtighten the vise.
(c) Using SST and a hammer, unstake the transfer gear nut. SST: 09930-00010 NOTICE:
| |
(d) Using a 30 mm socket wrench, remove the transfer gear nut.
17. REMOVE TRANSFER DRIVEN PINION
(a) Using SST and a press, remove the transfer driven pinion from the rear transfer output shaft sub-assembly.
SST: 09950-00020
SST: 09950-60011
09951-00240
SST: 09950-70010
09951-07100
NOTICE:
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
(a) Using SST and a press, remove the rear transfer output shaft dust deflector from the rear transfer output shaft sub-assembly. SST: 09950-00020 | |
19. REMOVE FRONT TRANSFER DRIVEN PINION BEARING
(a) Using SST and a press, remove the front transfer driven pinion bearing from the transfer driven pinion.
SST: 09950-00020
SST: 09950-60011
09951-00410
SST: 09950-70010
09951-07100
NOTICE:
Support the front transfer driven pinion bearing as shown in the illustration to avoid placing stress on the outer race.
(b) Remove the O-ring from the front transfer driven pinion bearing. | |
20. REMOVE TRANSFER OUTPUT SHAFT WASHER
(a) Remove the transfer output shaft washer from the transfer driven pinion.
21. REMOVE RING GEAR MOUNTING CASE BEARING RH
*a | Turn |
*b | Hold |
(a) Using SST, remove the ring gear mounting case bearing RH (inner race) from the transfer ring gear mounting case.
SST: 09950-40011
09951-04010
09952-04010
09953-04030
09954-04010
09955-04061
09957-04010
09958-04011
SST: 09950-60011
09951-00540
NOTICE:
(b) 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. SST: 09310-35010 |
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22. REMOVE RING GEAR MOUNTING CASE BEARING LH
*a | Turn |
*b | Hold |
(a) Using SST, remove the ring gear mounting case bearing LH (inner race) from the transfer ring gear mounting case.
SST: 09950-00020
SST: 09950-00030
NOTICE:
(b) 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. SST: 09636-20010 |
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23. REMOVE SHAFT SNAP RING
(a) Using a snap ring expander, remove the shaft snap ring.
24. REMOVE TRANSFER RING GEAR MOUNTING CASE
(a) Using SST and a press, remove the transfer ring gear mounting case from the transfer ring gear.
SST: 09950-60011
09951-00400
25. REMOVE BREATHER OIL DEFLECTOR
(a) Remove the 2 bolts and breather oil deflector from the transfer case.