Transfer Assembly

DISASSEMBLY AND REASSEMBLY

SERVICE POINTS OF REASSEMBLY




7. INSTALLATION OF TRANSFER CASE ADAPTER SUBASSEMBLY
Using a brush, apply a thin even coat of machine blue or minium to both tooth surfaces of the driven bevel gear.




5. INSTALLATION OF SPACER
Install the spacer which has been used so far.

4. INSTALLATION OF TRANSFER CASE SUBASSEMBLY




1. Tighten the transfer case adapter subassembly on the transfer case subassembly to the specified torque.




2. Using the special tool, turn the drive bevel gear shaft one turn each in the direction of normal and reverse rotation.

CAUTION: Do not rotate the drive bevel gear shaft more than one turn as it cause a blurred tooth contact pattern.




3. Make sure that the contact pattern of the driven bevel gear teeth is correct.

NOTE: See Tooth Contact Adjustment Procedure on next page for the standard tooth contact pattern.




4. Check to see if the backlash between the drive and driven bevel gears is up to specification.

Standard value Bevel gear set backlash: 0.08 - 0.13 mm (.0031 - .005 in.)

T00TH CONTACT ADJUSTMENT PROCEDURE




1. Standard tooth contact pattern
A: Small end
B: Drive side tooth surface (The side receiving force in forward motion)
C: Big end
D: Coast side tooth surface (The side receiving force in reverse motion)







2. Tooth contact pattern when driven bevel gear is too high
Possible cause:
The driven bevel gear is too close to the drive bevel gear.
Remedy:
Use a thicker spacer for the driven bevel gear mount adjustment so that the driven bevel gear is further away from the drive bevel gear.










3. Tooth contact pattern when driven bevel gear is too low
Possible cause:
The driven bevel gear is further away from the drive bevel gear than necessary.
Remedy:
Use a thinner spacer for the driven bevel gear mount adjustment so that the driven bevel gear is closer to the drive bevel gear.

NOTE:
1. If correct tooth contact cannot be obtained by replacement of spacer for adjusting driven bevel gear mount, change the spacers for adjustment of drive bevel gear preload and drive bevel gear mount adjustment to those of appropriate thickness as described below and adjust the tooth contact again.
- If the driven bevel gear height is still too small when the thinnest spacer for driven bevel gear mount adjustment [0.13 mm (.005 in.)] is used;
Change the spacer for drive bevel gear mount adjustment to the next thicker one and change the spacer for drive bevel gear preload adjustment to the next thinner one.
- If the driven bevel gear height is still too large when the thickest spacer for driven bevel gear mount adjustment [0.52 mm (.021 in.)] is used;
Change the spacer for drive bevel gear mount adjustment to the next thinner one and change the spacer for drive bevel gear preload adjustment to the next thicker one.
Repeat above steps until standard tooth contact pattern is obtained.
2. If the tooth contact pattern cannot be brought close to the standard pattern by the adjustment described above, replace the drive bevel gear and driven bevel gear as a set and adjust the tooth contact again.