Part 1

TRANSFER ASSEMBLY (4WD)








COMPONENTS

OVERHAUL
1. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
2. SEPARATE VANE PUMP ASSEMBLY
3. REMOVE RACK & PINION POWER STEERING GEAR ASSEMBLY
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 ASSEMBLY
10. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH





11. REMOVE ENGINE MOUNTING BRACKET RR
a. Remove the 3 bolts and engine mounting bracket RR.





12. REMOVE TRANSFER STIFFENER PLATE CENTER
a. Remove the 5 bolts and transfer stiffener plate center.
13. REMOVE TRANSFER STIFFENER PLATE RH
a. Remove the 4 bolts and transfer stiffener plate RH.
14. REMOVE TRANSFER ASSEMBLY
a. Remove the 6 nuts.
b. Using a plastic hammer, remove the transfer assembly from the transaxle assembly.

NOTICE:
^ Remove the transfer assembly from the transaxle assembly without tilting it.
^ When removing the transfer assembly, do not hold the oil seal parts on both sides of the assembly.

15. REMOVE TRANSFER & TRANSAXLE SETTING STUD BOLT
a. Remove the 4 transfer & transaxle setting stud bolt.





16. 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.





17. 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.





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 transfer extension housing.
22. REMOVE TRANSFER CASE STRAIGHT PIN
a. Remove the 4 transfer case straight pins from the transfer case.
23. FIX TRANSFER ASSEMBLY
a. Attach the transfer assembly 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 transfer extension housing sub-assembly.





25. REMOVE TRANSFER EXTENSION HOUSING TYPE T OIL SEAL
a. Using SST, remove the transfer extension housing type T oil seal from the transfer extension housing sub-assembly.
SST 09308-00010

NOTICE: Be careful of not damage the oil seal press in face of housing and the inner diameter of bush.





26. REMOVE TRANSFER EXTENSION HOUSING SUB-ASSEMBLY
a. Remove the 4 bolts.





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





27. INSPECT PRELOAD
a. 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): 0.30 to 0.53 Nm (3.0 to 5.4 kgf-cm, 2.6 to 4.7 inch lbs.)
b. Using SST and a torque wrench, measure the total preload.
SST 09326-20011
Preload (at starting): 0.49 to 0.86 Nm (5.0 to 8.8 kgf-cm, 4.3 to 7.6 inch lbs.)





28. INSPECT BACKLASH
a. Using a dial gauge, check the backlash of the ring gear.
Backlash: 0.10 to 0.18 mm (0.0039 to 0.0071 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 transfer case oil seal from the transfer 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 transfer case RH oil seal from the transfer 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 transfer 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 case.





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 rear bearing inner race and transfer pinion bearing spacer.





37. REMOVE TRANSFER DRIVEN PINION FRONT BEARING
a. Using SST and a press, remove the transfer driven pinion front bearing inner race.
SST 09950-00020





b. Using a brass bar and a hammer, tap the driven pinion front bearing 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 transfer ring gear mounting case.





b. 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, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00440)

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 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)

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 transfer case.

NOTICE: Place the brass bar at the 2 positions of the cutouts on the case.

e. Remove the ring gear mounting case plate washer.





40. INSPECT RUNOUT OF RING GEAR
a. Place the transfer ring gear mounting case on the V-block.
b. Using a dial gauge, check the runout of the ring gear.
Maximum runout: 0.06 mm (0.0024 inch)





41. REMOVE RING GEAR
a. Make matchmarks on the transfer 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 transfer 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 transfer ring gear mounting case on the V-block.
b. Using a dial gauge, check the runout of the ring gear.
Maximum runout: 0.14 mm (0.0055 inch)





43. REMOVE TRANSFER DRIVEN PINION REAR BEARING
a. Using a brass bar and a hammer, tap the 2 positions on the driven pinion rear bearing outer race before removing from the transfer case.

NOTICE: Place the brass bar at the 2 positions of the cutouts on the case.





44. INSTALL TRANSFER DRIVEN PINION REAR BEARING
a. 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)

NOTICE: Keep the transfer case horizontally using tip of wood, etc..

b. Apply gear oil to the driven pinion rear bearing outer race.
45. INSTALL TRANSFER OUTPUT WASHER
a. Install a transfer output washer to the transfer case.

HINT: Install the same washer as the previous one.

b. Apply gear oil to the transfer output washer.





46. INSTALL TRANSFER DRIVEN PINION FRONT BEARING
a. Apply gear oil to the inner surface of the transfer case.
b. Using SST, install the transfer driven pinion front bearing outer race to the transfer 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 front bearing inner race into the driven pinion.
SST 09506-30012





47. INSTALL DRIVEN PINION
a. Install the driven pinion to the transfer case.





b. Install a new transfer pinion bearing spacer and driven pinion rear bearing 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 to 355 Nm (2,647 to 3,616 kgf-cm, 191 to 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 pre load, 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: 0.53 to 0.97 Nm (5.4 to 9.9 kgf-cm, 4.7 to 8.6 inch lbs.)
Reused bearing: 0.30 to 0.53 Nm (3.0 to 5.4 kgf-cm, 2.6 to 4.7 inch lbs.)

HINT:
^ Using a torque wrench with a fulcrum length of 160 mm (6.3 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.