Disassembly and Reassembly

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 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 (0.0031 - 0.0051 inch)

>A< O-Ring Installation

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

>B< Extension Housing Installation





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