Part 1
OVERHAUL1. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
2. SEPARATE VANE PUMP ASSY
3. REMOVE RACK & PINION POWER STEERING GEAR ASSY
4. REMOVE FRONT SUSPENSION CROSSMEMBER W/CENTER MEMBER
5. REMOVE MANIFOLD STAY
6. REMOVE OXYGEN SENSOR
7. REMOVE EXHAUST MANIFOLD HEAT INSULATOR No. 1
8. REMOVE EXHAUST MANIFOLD
9. REMOVE STARTER ASSY
10. REMOVE FRONT DRIVE SHAFT ASSY RH
11. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
a. Remove the 3 bolts and engine mounting bracket.
12. REMOVE TRANSFER STIFFENER PLATE CENTER
a. Remove the 5 bolts and stiffener plate center.
13. REMOVE TRANSFER STIFFENER PLATE RH
a. Remove the 4 bolts and stiffener plate RH.
14. REMOVE TRANSFER ASSY
a. Remove the 6 nuts.
b. Using a plastic hammer, remove the transfer assy from the transaxle assy.
NOTICE:
^ Remove the transfer assy horizontally from the transaxle assy.
^ When removing, do not touch the both sides of oil seal part of transfer assy.
15. REMOVE TRANSFER & TRANSAXLE SETTING STUD BOLT
a. Remove the 4 stud bolts.
16. REMOVE TRANSFER CASE No. 1 PLUG
a. Remove the transfer case No. 1 plug.
b. Remove the gasket from the transfer case No. 1 plug.
17. REMOVE TRANSFER CASE No. 2 PLUG
a. Remove the transfer case No. 2 plug.
b. Remove the gasket from the transfer case No. 2 plug.
18. REMOVE TRANSFER DRAIN PLUG
a. Remove the transfer drain plug.
b. Remove the gasket from the transfer drain plug.
19. REMOVE TRANSFER CASE BREATHER PLUG
20. REMOVE TRANSFER CASE COVER No. 1
a. Remove the 8 bolts.
b. Using a brass bar and a hammer, remove the transfer case cover No. 1 from the case.
NOTICE: Place the brass bar on the rib part of the case.
c. Remove the bolt and breather oil deflector.
21. REMOVE TRANSFER DYNAMIC DAMPER
a. Remove the 3 bolts and transfer dynamic damper from the extension housing.
22. REMOVE TRANSFER CASE STRAIGHT PIN
a. Remove the 4 transfer case straight pins from the transfer case.
23. FIX TRANSFER ASSY
a. Attach the transfer assy to the overhaul attachment.
24. REMOVE TRANSFER EXTENSION HOUSING DUST DEFLECTOR
a. Using a plastic hammer, remove the transfer extension housing dust deflector from the extension housing.
25. REMOVE TRANSFER EXTENSION HOUSING TYPE T OIL SEAL
a. Using SST, remove the oil seal from the extension housing.
SST 09308-00010
NOTICE: Be careful of not damaging the oil seal press in face of housing and the inner diameter of bush.
26. REMOVE TRANSFER EXTENSION HOUSING SUB-ASSY
a. Remove the 4 bolts.
b. Using a plastic hammer, remove the extension housing sub-assy from the case.
27. INSPECT PRELOAD
a. Using SST and a torque wrench, measure the preload of the backlash between the drive pinion and ring gear.
SST 09326-20011
Preload (at starting): 0.32 - 0.57 Nm (3 - 6 kgf-cm, 2.8 - 5.0 inch lbs.)
b. Using SST and a torque wrench, measure the total preload.
SST 09326-20011
Preload (at starting): 0.53 - 0.94 Nm (5 - 10 kgf-cm, 4.7 - 8.3 inch lbs.)
28. INSPECT BACKLASH
a. Using a dial indicator, check the backlash of the ring gear.
Backlash: 0.10 - 0.15 mm (0.0039 - 0.0059 inch)
If the backlash is not within the specification, adjust the side bearing preload or repair as necessary.
NOTICE: Check at least 3 positions on the circumference of the ring gear.
29. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVEN PINION
a. Coat 3 or 4 teeth at 4 different positions on the ring gear with red lead.
b. Rotate the ring gear inspect the tooth pattern.
30. REMOVE TRANSFER CASE OIL SEAL
a. Using SST, remove the oil seal from the case.
SST 09308-00010
NOTICE: Do not damage the oil seal press in face of case.
31. REMOVE TRANSFER CASE RH OIL SEAL
a. Using SST, remove the oil seal from the case.
SST 09308-00010
NOTICE: Do not damage the oil seal press in face of case.
32. REMOVE BEARING CAP
a. Remove the 2 bolts and the bearing cap.
33. REMOVE TRANSFER OUTPUT SHAFT SPACER No. 1
a. Using SST, a screwdriver and a hammer, remove the transfer output shaft spacer No. 1.
SST 09504-22011
NOTICE: Protect with waste for not damaging the case.
34. REMOVE TRANSFER RING GEAR MOUNTING CASE WASHER No. 2
35. REMOVE TRANSFER RING GEAR MOUNTING CASE
a. Remove the transfer ring gear mounting case from the transfer assy.
36. REMOVE DRIVEN PINION
a. Using SST and a hammer, unstake the gear nut.
SST 09930-00010
HINT:
^ Using SST with the flat side facing outward.
^ Do not machine the tip of SST with a grinder, etc.
b. Using SST, remove the gear nut.
SST 09326-20011, 09556-16030
c. Using a press, remove the driven pinion, transfer driven pinion bearing rear inner race and transfer pinion bearing spacer.
37. REMOVE BEARING (FOR TRANSFER DRIVEN PINION FRONT)
a. Using SST and a press, remove the transfer driven pinion bearing front inner race.
SST 09950-00020
b. Using a brass bar and a hammer, tap the driven pinion bearing front outer race to remove from the case.
NOTICE: Place the brass bar at the 2 positions of the cutouts on the case.
38. REMOVE TRANSFER OUTPUT WASHER
39. REMOVE RING GEAR MOUNTING CASE BEARING
a. Remove the ring gear mounting case bearing RH outer race from the ring gear mounting case assy.
b. Using SST, remove the ring gear mounting case bearing RH inner race from the ring gear mounting case assy.
SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00400, 09951-00450)
NOTICE: Using SST (09953-04020) with its screw and tip applied to grease.
c. Using SST, remove the ring gear mounting RH inner race from the ring gear mounting case assy.
SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00400, 09951-00450)
NOTICE: Using SST (09953-04020) with its screw and tip applied to grease.
d. Using a brass bar and a hammer, tap the 2 positions of the ring gear mounting case bearing LH outer race to remove from the case.
NOTICE: Place the brass bar at the 2 positions of the cutouts on the case.
e. Remove the case washer.
40. INSPECT RUNOUT OF RING GEAR
a. Place the ring gear mounting case assy on the V-block.
b. Using a dial indicator, check the runout of the ring gear.
Maximum runout: 0.06 mm (0.0024 inch)
41. REMOVE RING GEAR
a. Make matchmarks on the ring gear mounting case and the ring gear.
b. Remove the 10 bolts.
c. Using a plastic hammer, tap on the ring gear to separate it from the ring gear mounting case.
NOTICE: Do not damage the tooth face of the ring gear.
42. INSPECT RUNOUT OF TRANSFER RING GEAR MOUNTING CASE
a. Place the ring gear mounting case assy on the V-block.
b. Using a dial indicator, check the runout of the ring gear.
Maximum runout: 0.14 mm (0.0055 inch)
43. REMOVE BEARING (FOR TRANSFER DRIVEN PINION REAR)
a. Using a brass bar and a hammer, tap the 2 positions on the driven pinion bearing rear outer race before removing from the case.
NOTICE: Place the brass bar at the 2 positions of the cutouts on the case.
44. INSTALL BEARING (FOR TRANSFER DRIVEN PINION REAR)
a. Using SST and a press, press the driven pinion bearing rear outer race into the case.
SST 09950-60010 (09951-00620), 09950-70010 (09951-07150)
NOTICE: Keep the transfer case horizontally using tip of wood, etc.
b. Apply gear oil to the driven pinion bearing rear outer race.
45. INSTALL TRANSFER OUTPUT WASHER
a. Install a washer to the case.
HINT: Install the same washer as the previous one.
b. Apply gear oil to the washer.
46. INSTALL BEARING (FOR TRANSFER DRIVEN PINION FRONT)
a. Apply gear oil to the inner surface of the transfer case.
b. Using SST, install the driven pinion bearing front outer race to the case with a bolt and a nut.
SST 09950-60010 (09951-00610, 09951-00620, 09951-00650), 09950-60020 (09951-00680)
c. Using SST and a press, press the driven pinion bearing front inner race into the driven pinion.
SST 09506-30012
47. INSTALL DRIVEN PINION
a. Install the driven pinion to the case.
b. Install a new pinion bearing spacer and driven pinion bearing rear inner race to the driven pinion.
HINT: Install the pinion bearing spacer with the larger inner diameter coming to the front side.
c. Using SST, install a new gear nut.
SST 09326-20011, 09556-16030
Torque: 260 - 355 Nm (2,647 - 3,616 kgf-cm, 191 - 262 ft. lbs.)
HINT:
^ Using a torque wrench with a fulcrum length of 380 mm (15.03 inch).
^ This torque value is effective in the case that SST is parallel to a torque wrench.
NOTICE: Do not stake the nut until the final adjustment of the preload, tooth contact and backlash is completed.
48. ADJUST DRIVEN PINION PRELOAD
a. Using SST and a torque wrench, measure the driven pinion preload.
SST 09326-20011
Preload (at starting): New bearing: 0.52 - 0.97 Nm (5 - 10 kgf-cm, 4.6 - 8.6 inch lbs.)
Reused bearing: 0.30 - 0.52 Nm (3 - 5 kgf-cm, 2.7 - 4.6 inch lbs.)
HINT:
^ Using a torque wrench with a fulcrum length of 160 mm (63 inch).
^ This torque value is effective in case that SST is parallel to torque wench.
^ If the preload is not sufficient, adjust the driven pinion by tightening the lock nut by 5° to 10° and measuring the preload until the preload is with in the standard value.
^ If the preload is more than standard value, replace the spacer with a new one.
^ Even if the tightening torque of gear nut exceeds the specified torque, if the preload is not enough, loosen the gear nut once and apply rust preventive oil or gear oil super to the gear nut and to the screw or bearing surface of driven pinion. Then do the procedure again. If the tightening torque is smaller than the specified value, replace the pinion bearing spacer with a new one and adjust it.
49. INSTALL RING GEAR
a. Clean the contact surface of the ring gear and transfer ring gear mounting case.
b. Heat the ring gear in water and boil for 10 minutes.
c. Carefully remove the ring gear from the water.
d. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the transfer ring gear mounting case.
e. Install the 10 bolts.
Torque: 77.5 Nm (790 kgf-cm, 57 ft. lbs.)
NOTICE:
^ Tighten the bolts in diagonal order in splitting several times.
^ After the ring gear has well cooled down, tighten the bolts.
^ Make paint marks, etc. do the procedure while checking the bolts retightened.
50. INSTALL RING GEAR MOUNTING CASE BEARING
a. Using SST and a press, press the ring gear mounting case bearing RH inner race into the ring gear mounting case.
SST 09950-60010 (09951-00420)
b. Install the ring gear mounting case bearing RH outer race to the ring gear mounting case.
c. Apply gear oil to the ring gear mounting case bearing RH.
d. Using SST and a press, press the ring gear mounting case LH inner race into the ring gear mounting case.
SST 09223-00010, 09726-40010
e. Install the washer to the case.
HINT: Use a new washer with the same thickness as the removed one when installation.
f. Using SST and a press, press the ring gear mounting case bearing LH outer race into the case.
SST 09950-60010 (09951-00620), 09950-70010 (09951-07200)
g. Apply gear oil to the ring gear mounting case bearing.