Unit

TRANSFER - 4WD





DISASSEMBLY AND REASSEMBLY

REASSEMBLY SERVICE POINTS

BACKLASH ADJUSTMENT





(1) Apply a light and uniform coat of machine blue or red lead to the driven bevel gear teeth (both sides) using a brush.





(2) Install the spacer that has been used.





(3) Align the transfer case and drive bevel gear mating marks.





(4) Align the transfer case adapter and drive bevel gear mating marks.
(5) Assemble the transfer case and transfer case adapter and tighten to the specified torque.





(6) With the mating marks aligned as in step (3) confirm that the transfer case and drive bevel gear mating marks are matched looking from the cover.





(7) Turn the drive bevel gear shaft (one forward turn, one reverse turn) using the special tool.

NOTE: Do not turn the drive bevel gear shaft more than one turn in either direction as this will cause an unclear tooth contact pattern.





(8) Check to see if the drive bevel gear tooth contact is normal.

NOTE Refer to the TOOTH CONTACT ADJUSTMENT PROCEDURES (below) for the standard tooth contact.





(9) Check to see if the drive bevel gear and driven bevel backlash is as specified.

Standard value:
Bevel gear set backlash
0.08-0.13 mm (.0031 - .0051 in.)

A. 0-RING INSTALLATION

CAUTION: Apply transmission oil to the 0-ring before installation.

B. EXTENSION HOUSING INSTALLATION





(1) Apply sealant to the adapter flange surface and install the extension housing.

Specified sealant:
Mitsubishi genuine Sealant Part No. MD997740 or equivalent

NOTE: Squeeze out sealant from the tube uniformly and continuously in adequate amount.

C. SEALANT APPLICATION TO COVER GASKET





Specified sealant:
3M ATD Part No.8660 or equivalent

TOOTH CONTACT ADJUSTING PROCEDURES





1. Standard tooth contact pattern
A .... Small end side
B .... Drive side tooth face
(Side on which force acts when running forward)
C .... Big end side
D .... Coast side tooth face
(Side on which force acts when reversing)





2. Tooth contact pattern produced when drive bevel gear height is too large

Cause
The driven bevel is too close to the drive bevel gear.





Remedy
Use thicker bevel gear mount adjusting spacer to separate the driven bevel gear more from the drive bevel gear.





3. Tooth contact pattern produced when driven bevel gear height is too small

Cause
The driven bevel gear is too separated from the drive bevel gear.





Remedy
Use thinner driven bevel gear mount adjusting spacer to bring the driven bevel gear more closer to the drive bevel gear.

NOTE:





(1) If correct tooth contact cannot be obtained even by change of the driven bevel gear mount adjusting spacer, increase or decrease or decrease the drive bevel gear preload adjusting spacer and the drive bevel gear mount adjusting spacer as described below and then adjust tooth contact again.
- When the driven bevel gear height is too small even it the thinnest driven bevel gear mount adjusting spacer 0.13 mm (.0051 in.) is used:
Replace the drive bevel gear mount adjusting spacer that is in use with one that is one rank thicker and replace the drive bevel preload adjusting spacer that is in use with one that is one rank thinner.
- When the driven bevel gear height is too large even if the thickest driven bevel gear mount adjusting spacer 0.52 mm (.025 in.) is used:
Replace the drive bevel gear mount adjusting spacer that is in use with one that is one rank thinner and replace the drive bevel gear preload adjusting spacer that is in use with one that is one rank thicker.
(2) Repeat above steps until the tooth contact pattern equal or close to the standard pattern is obtained.
(3) If the tooth contact pattern cannot be adjusted close to the standard pattern by above adjustment, replace the drive bevel gear and driven bevel gear as a set and readjust the tooth contact.