Transfer Clutch

Transfer Clutch
REMOVAL
Remove the transmission assembly from vehicle.
Remove the extension case and remove the transfer clutch.

INSTALLATION
Select the thrust needle bearing.
Install the transfer clutch assembly to the case.





(A) Transfer clutch
(B) Extension case
Replace with new gasket, and tighten bolts to secure the case.
Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft. lbs.)





Install the transmission assembly to vehicle.

DISASSEMBLY
Remove the seal ring.





(A) Seal ring
(B) Transfer clutch
Using a press and ST, remove the ball bearing.
ST 32005091 REMOVER





Remove the snap ring, and take out the pressure plate, drive plates, and driven plates.





(A) Snap ring
(B) Transfer clutch
Remove the snap ring with ST1, ST2 and ST3, and take out the return spring and transfer clutch piston seal.
ST1 32005082 PLIERS
ST2 32005075 COMPRESSOR
ST3 32005072 SEAT





(A) Snap ring
(B) Transfer piston seal
Apply compressed air to the rear drive shaft to remove the piston.





ASSEMBLY
Install the transfer clutch piston.





(A) Transfer clutch piston
(B) Rear drive shaft
Install return spring to transfer piston.





(A) Return spring
(B) Rear drive shaft

Apply ATF to the transfer clutch piston seal lip and install it.





(A) Transfer clutch piston seal
(B) Rear drive shaft

Install ST to rear drive shaft.
ST 32005128 SNAP RG OUTER GUIDE





(A) Transfer clutch
Install snap ring to ST.
ST 32005128 SNAP RG OUTER GUIDE





(A) Snap ring
(B) Transfer clutch

Using ST1 and ST2, install snap ring to rear drive shaft.
ST1 32005128 SNAP RG OUTER GUIDE
ST2 32005127 INSTALLER





(A) Snap ring
(B) Transfer clutch
Install the driven plates, drive plates, pressure plate and snap ring.





(A) Snap ring
Apply compressed air to see if the assembled parts move smoothly.





Check clearance between snap ring and pressure plate.
Press-fit a new ball bearing with ST.
ST 32005175 INSTALLER





(A) Ball bearing
Coat a new seal ring with Vaseline, and install it in the seal ring groove of the shaft.

Note: Do not expand the seal ring excessively when installing.





(A) Snap ring





(B) Transfer clutch
Install the transfer clutch assembly without damaging seal ring.

(A) Transfer clutch
(B) Extension case

INSPECTION
^ Check the drive plate facing for wear and damage.
^ Check the snap ring for wear, return spring for permanent set and breakage, and return spring for deformation.
^ Check the D-ring for damage.
^ Measure the extension end play and adjust it to within specifications.

Inspect clearance between snap ring and pressure plate.
Before measuring clearance, place the same thickness of shim on both sides to prevent pressure plate from tilting.

If the clearance is not within specification, adjust it by selecting a suitable pressure plate on the transfer clutch piston side. If it exceeds the service limit, replace the drive plate with new one and adjust it within the specification by selecting the pressure plate.

Initial standard: 0.7 - 1.1 mm (0.028 - 0.043 inch)
Limit thickness: 1.6 mm (0.063 inch)





Check if the tight corner braking does not occur when the vehicle is started with steering wheel held at fully turned position. If tight corner braking occurs, perform the following procedures.

With the steering wheel held at fully turned position, drive the vehicle in "D" range and with vehicle speed at approximately 5 km/h (3 MPH) in both clockwise and counterclockwise directions for approximately ten times each, while repeating acceleration and braking intermittently.

If the tight corner braking still persists, drive the vehicle again in a circle for several laps.





ADJUSTMENT

MPT MODEL





Measure distance "A" from end of extension case and rear drive shaft with ST.
ST 32005073 GAUGE

A: Measured value





Measure the distance "B" from the transmission case mating surface to the reduction drive gear end surface with ST1 and ST2.
ST1 32005073 GAUGE
ST2 32005133 GAUGE

B: Measured value
Calculation formula:

Note:

^ Calculate "T":
T= A - B + 35.4 mm
[T = A - B + 1.3937 inch]

T: Thrust needle bearing thickness
A: Distance from end of extension case to end of rear drive shaft
B: Distance from end of transmission case to end of reduction drive gear

Example:

When, A = 33.6 mm (1.3228 inch), B = 65.05 mm (2.5610 inch)
T = 33.6 - 65.05 + 35.4 = 3.95
T = 1.3228 - 2.5610 + 1.3937 = 0.1555]

After calculating of "H" becomes 3.95 mm (0.1555 inch), therefore select bearing thickness of 3.8 mm (0.150 inch) on, the valve.
^ Calculation formula for "T" is applied when measuring using ST (32005073 GAUGE, 32005133 GAUGE). When not using ST, apply
T: (A - a + 0.45 mm) - (B - H
T: (A - a + 0.0177 inch) - (B - - H].
T: Thrust needle bearing thickness
A: Distance from end of extension case to end of reduction drive shaft
B: Distance from end of transmission case to end of rear drive shaft
a: Collar thickness used when measuring "A"
B: Collar thickness used when measuring "B"
0.45 (0.0177): Gasket thickness (mm (in))
H: Shim clearance





VTD MODEL

Insert the rear driveshaft into the reduction drive gear and center differential assembly.





(A) Rear drive shaft
(B) Center differential carrier

Using the special tool, measure the distance "A" between the mating surface of extension case and multi-plate clutch (LSD) piston.

ST 32005073 GAUGE





A: Measured value

Using the ST, measure the distance "B" between the mating surface of transmission case and reduction drive gear edge.

ST 32005073 GAUGE





B: Measured value

Note

^

Calculation of "T":
When clearances are 0.05 mm (0.0020 in), select up to four adjusting shims from the table, suitable for clearance value.

When clearances are 0.05 mm (0.0020 in)
T = A - B + 0.40 mm
[T = A - B + 0.0157 in]
When clearances are 0.25 mm (0.0098 in)
T = A - B + 0.20 mm
[T = A - B + 0.0079 in]

T: Shim clearance

A: Distance between extension case edge and rear driveshaft edge
B: Distance between transmission case edge and reduction drive gear edge

T: Shim thickness
0.05 - 0.25 mm (0.0020 - 0.0098 in)

Example:

When, A = 90.50 mm (3.5630 in), B = 90.35 mm (3.5571 in)
Calculation for 0.05 mm (0.0020 in) of clearance
T = 90.50 - 90.35 + 0.4 = 0.55
[T = 3.5630 - 3.5571 + 0.0157 = 0.0216]

Calculation when clearance is 0.25 mm (0.0098 in)
T = 90.50 - 90.35 + 0.2 = 0.35
[T = 3.5630 - 3.5571 + 0.0079 = 0.0138]

Calculation formula for "T" is applied when measuring using ST (32005073 GAUGE). When not using ST, apply
T = (A - a + 0.45 mm) - (B - �) - H
[T = (A - a + 0.0177 in) - (B - �) - H].
T: Thrust needle bearing thickness

A: Distance from end of extension case to rear drive shaft ball bearing outer ring contact surface
B: Distance from end of transmission case to end of rear drive shaft ball bearing
a: Collar thickness used when measuring "A"
�: Collar thickness used when measuring "B" 0.45: Gasket thickness (mm)





H: Shim clearance
After calculation, the value of "T" becomes between 70.35 mm (0.0138 in) and 0.55 mm (0.0216 in), therefore select two shims with thickness of 0.2 mm (0.010 in) or one shim with thickness of 0.5 mm (0.020 in).