Disassembly

DISASSEMBLY





1. REMOVE GASKET





2. REMOVE DIFFERENTIAL SIDE GEAR INTERMEDIATE NO.2
3. REMOVE CASE COVER NO.1





a. Remove the 8 bolts.





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

NOTICE: Be careful not to damage the transfer case and case cover No.1.





c. Remove a bolt and breather oil deflector from the case cover No.1.
4. REMOVE PIN
5. REMOVE STUD BOLT
6. INSTALL TRANSFER ON OVERHAUL ATTACHMENT
7. REMOVE EXTENSION HOUSING





a. Using plastic hammer, remove the dust deflector from the extension housing.





b. Using SST, remove the oil seal from the extension housing.
SST 09308-00010

NOTICE: Be careful not to damage the extension housing.





c. Remove the 4 bolts.





d. Using a plastic hammer, remove the extension housing.





8. CHECK PRELOAD
a. Using SST and a torque wrench, measure the driven pinion preload of the backlash between the driven pinion and ring gear.
SST 09326-20011
Preload (at starting): 0.9 - 1.3 Nm (9 - 13 kgf-cm, 7.8 - 11.2 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 a torque wrench.

b. Using SST and the torque wrench, measure the total preload.
SST 09326-20011
Total preload (at starting): 1.0 - 1.6 Nm (10 - 16 kgf-cm, 8.9 - 13.8 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 a torque wrench.





9. CHECK RING GEAR BACKLASH
Using a dial indicator, measure the ring gear backlash.
Backlash: 0.10 - 0.15 mm
10. CHECK TOOTH CONTACT
11. REMOVE CENTER DIFFERENTIAL LOCK SLEEVE





a. Using a snap ring pliers, remove the shaft snap ring.





b. Using SST, remove the center differential lock sleeve.
SST 09308-00010

NOTICE: Be careful not to damage the center differential lock sleeve.





c. Using a screwdriver, remove the O-ring from the center differential lock sleeve.

NOTICE: Be careful not to damage the center differential lock sleeve.





12. REMOVE OIL SEAL
Using SST remove the oil seal from the transfer case.
SST 09308-00010

NOTICE: Be careful not to damage the transfer case.

13. REMOVE BEARING RETAINER RH





a. Using SST, remove the oil seal from the bearing retainer RH.
SST 09308-00010

NOTICE: Be careful not to damage the bearing retainer.





b. Remove the 7 bolts and bearing retainer RH from the transfer case.





c. Using a screwdriver, remove 2 O-rings from the bearing retainer RH.

NOTICE: Be careful not to damage the bearing retainer RH.





d. Using the soft jaws, hold the bearing retainer RH in a vise.
e. Using SST, remove the outer race, washer and oil seal from the bearing retainer RH.
SST 09308-00010

NOTICE: Be careful not to damage the bearing retainer RH.





f. Using snap ring pliers, remove the snap ring.
g. Remove the side gear shaft holder bearing from the bearing retainer RH.





14. REMOVE CENTER DIFFERENTIAL CONTROL COUPLING





15. REMOVE TAPERED ROLLER BEARING LH AND RH
Using SST, remove the tapered roller bearing inner race LH and RH.
SST 09950-00020, 09950-00030, 09950-60010 (09951-00360)





16. CHECK RING GEAR RUNOUT
Using a dial indicator, check the ring gear runout.
Maximum runout: 0.1 mm (0.004 inch)
17. REMOVE RING GEAR





a. Place matchmarks on both the ring gear and the center differential control coupling.
b. Remove the 12 bolts.





c. Using a plastic hammer, remove the ring gear.





18. CHECK CENTER DIFFERENTIAL CONTROL COUPLING RUNOUT
Using a dial indicator, check the center differential control coupling runout.
Maximum runout: 0.07 mm (0.0028 inch)
19. REMOVE DRIVEN PINION





a. Using SST and a hammer, unstake the lock nut.
SST 09930-00010 (09931-00010, 09931-00020)





b. Using SST, remove the lock nut.
SST 09326-20011, 09556-16030





c. Using a press, remove the driven pinion, the rear bearing inner race and the spacer.

NOTICE:
- Place a waste cloth inside the case to prevent the driven pinion from dropping.
- Keep the case level using a wood plate.





d. Using SST and a press, remove the front bearing inner race from the driven pinion.
SST 09950-00020





20. REMOVE BEARING OUTER RACE LH
Using a brass bar and a hammer, remove the outer race and the washer.





21. REMOVE FRONT BEARING OUTER RACE
Using a brass bar and a hammer, remove outer race and washer.





22. REMOVE REAR BEARING OUTER RACE
Using a brass bar and a hammer, remove outer race.