Transfer Clutch

NOTE: The content of this article/image reflects the changes called out by TSB 18-88-05.

Transfer Clutch

REMOVAL
1) Remove the transmission assembly from the vehicle.





2) Remove the rear vehicle speed sensor.





3) Separate transmission case and extension case sections.





4) Take out the transfer clutch by lightly tapping the end of the rear drive shaft.

INSTALLATION
1) Select the thrust needle bearing.





2) Install the transfer clutch assembly to the case.





3) Tighten bolts to secure the case.
Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft. lbs.)
4) Install the transmission assembly to the vehicle.

DISASSEMBLY





1) Remove the seal ring.





2) Using a press and ST, remove the ball bearing.
ST 498077600 REMOVER





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





4) Remove the snap ring with ST1, ST2 and ST3, and take out the return spring and transfer clutch piston seal.
ST1 399893600 PLIERS
ST2 398673600 COMPRESSOR
ST3 398623600 SEAT





5) Apply compressed air to the rear drive shaft to remove the piston.

ASSEMBLY





1) Install the transfer clutch piston.





2) Install return spring to transfer piston.





3) Install transfer clutch piston seal.





4) Install ST to rear drive shaft.
ST 499257300 SNAP RING OUTER GUIDE





5) Install snap ring to ST.
ST 499257300 SNAP RING OUTER GUIDE





6) Using ST1 and ST2, install snap ring to rear drive shaft.
ST1 499257300 SNAP RING OUTER GUIDE
ST2 499247400 INSTALLER





7) Install the driven plates, drive plates, pressure plate and snap ring.





8) Apply compressed air to see if the assembled parts move smoothly.
9) Inspect clearance between snap ring and pressure plate.





10) Press-fit a new ball bearing with ST.
ST 899580100 INSTALLER





11) Coat a new seal ring with petrolatum, and install it in the seal ring groove of the shaft.

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





12)Install the transfer clutch assembly without damaging seal ring.

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

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








3) If the clearance is not within specification, adjust it by selecting a suitable pressure plate on the transfer clutch piston side.
Standard: 0.7 - 1.1 mm (0.028 - 0.043 inch)
Service limit: 1.6 mm (0.063 inch)
4) Check if 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.
1) 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.
2) If the tight corner braking still persists, drive the vehicle again in a circle for several laps.

ADJUSTMENT
MPT MODEL





1) Using the ST, measure the distance "A" from the end surface of ST to the end surface of rear drive shaft.






2) Using the ST1 and ST2, measure the distance "B" from the transmission case mating surface to the end surface of ST.

3) Calculation formula:

NOTE:
Calculate"T":
T = A - B + 35.4 mm
[T = A - B + 1.3937 in]
T: Thrust needle bearing thickness
A: Distance from the end surface of ST to the end surface of rear drive shaft
B: Distance from the mating surface of transmission case to end of the end surface of ST
Example:
When, A = 33.6 mm (1.3228 in), B = 65.05 mm (2.5610 in)
T = 33.6 - 65.05 + 35.4 = 3.95
[T = 1.3228 - 2.5610 + 1.3937 = 0.1555]
After calculation, the value of "H" becomes 3.95, therefore select bearing thickness of 3.8.
Calculation formula for "T" is applied when measuring using ST (398643600 GAUGE, 499577000 GAUGE). When not using ST, apply
T = (A - a + 0.45 mm) - (B - b) - H
[T = (A - a + 0.0177 in) - (B - b) - H].
T: Thrust needle bearing thickness
A: Distance from the end surface of collar as substitute for ST to the end surface of reduction drive shaft
B: Distance from the mating surface of transmission case to the end surface of collar as substitute for ST
a: Collar thickness used when measuring "A"
b: Collar thickness used when measuring "B"
0.45: Gasket thickness (mm)
H: Shim clearance







VTD MODEL





1) Insert the rear drive shaft into the reduction drive gear and center differential assembly.





2) Using the ST, measure the distance "A" from the end surface of ST to the ball bearing outer ring contact surface of rear drive shaft.
ST 398643600 GAUGE





3) Using the ST, measure the distance "B" from the mating surface of transmission case to the end surface of ST.


4) Calculation formula:

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 from the end surface of ST to the ball bearing outer ring contact surface of rear drive shaft
B: Distance from the mating surface of transmission case to the end surface of ST
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 (398643600 GAUGE). When not using ST, apply
T = (A - a + 0.45 mm) - (B - b) - H
[T = (A - a + 0.0177 in) - (B - b) - H].
T: Thrust needle bearing thickness
A: Distance from the end surface of collar as substitute for ST to the rear drive shaft ball bearing outer ring contact surface
B: Distance from the mating surface of transmission case to the end surface of collar as substitute for ST
a: Collar thickness used when measuring "A"
b: Collar thickness used when measuring "B"
0.45: Gasket thickness (mm)
H: Shim clearances






After calculation, the value of "T" becomes between 0.35 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)