Transfer Lower Valve Body
COMPONENTS
SPECIFICATIONS OF TRANSFER LOWER VALVE BODY SPRINGS AND RETAINERS
NOTE: During reassembly please refer to the spring specifications above to help discriminate between the different springs.
ASSEMBLY OF TRANSFER VALVE BODY
1. INSTALL PLATE AND NEW GASKETS ON TRANSFER LOWER VALVE BODY
Install a new gasket and plate and then the other new gasket.
NOTE: Both gaskets are the same.
2. INSTALL TRANSFER LOWER VALVE BODY
Each bolt length (mm (in.)) is indicated in the figure.
a. Lower the transfer lower valve body into place.
b. Hand tighten the eight bolts first. Then, tighten them with a torque wrench.
Torque: 67 kg.cm. (58 in.lb., 6.6 N.m)
ASSEMBLY OF TRANSFER LEFT CASE
1. INSTALL SHIFT FORK SHAFT TO SHIFT FORK
a. Insert the shift fork shaft into the shift fork.
b. Install the ball, spring and head plug.
c. Tighten the plug.
Torque: 250 kg.cm. (18 ft.lb., 25 N.m)
2. INSTALL SHIFT FORK SHAFT, SHIFT FORK AND SLEEVE
3. INSTALL TRANSFER SHIFT LEVER
a. Coat the lip of new oil seal with MP grease.
b. Using a 17 mm (0.67 in.) socket wrench and hammer, drive in the oil seal as shown.
c. Install transfer shift lever.
NOTE: Engage shift fork and transfer shift lever.
d. Install and tighten the lock bolts.
Torque: 40 kg.cm. (35 in.lb., 3.9 N.m)
4. INSTALL TRANSFER VALVE BODY ASSEMBLY
a. Install the new transfer case gaskets and valve body strainer.
b. Install the new transfer valve body gasket.
c. Install the transfer valve body assembly.
d. Tighten the bolts.
Torque: 110 kg.cm. (8 ft.lb., 11 N.m)
5. INSTALL CENTER DIFFERENTIAL CONTROL SOLENOIDS
a. Install the four new O-rings to the solenoids.
b. Coat the O-rings with ATF.
c. Install the solenoids.
Torque: 145 kg.cm. (10 ft.lb., 14 N.m)
ASSEMBLY OF COMPONENT PARTS
1. INSTALL CASE SIDE
a. Install the plate washer.
NOTE: First install a washer of the same thickness as before.
b. Using SST and a press, press in the outer race.
SST 09316-60010 (09316-00010, 09316-00060)
2. INSTALL RIGHT CASE SIDE
a. Using SST and a press, press in outer race as shown.
SST 09316-60010 (09316-00010, 09316-00060)
b. Install the bearing adjusting nut and oil reserver, until it touches the outer race.
3. ADJUST RING GEAR BACKLASH
a. Install the two shims to the driven pinion bearing cage assembly.
NOTE: First install shims of the same thickness as before.
b. Install the driven pinion bearing cage.
Torque: 400 kg.cm. (29 ft.lb., 39 N.m)
NOTE: Do not install the O-ring.
c. Install the ring gear mounting case and center differential case.
d. Using a dial indicator, measure the ring gear backlash.
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 in.)
Plate Washer Thickness In mm:
e. Referring to the table above, select the plate washer which will ensure that the backlash is within specification. Try to select a washer of the same size.
4. ADJUST TOTAL PRELOAD
a. Install the transfer right case.
b. Install and torque the ten bolts.
Torque: 450 kg.cm. (33 ft.lb., 44 N.m)
NOTE: Do not apply seal packing and do not install gasket. Each bolt length (mm (in.)) is indicated in the figure.
c. Using SST and a spring tension gauge, measure the total preload.
SST 09326-20011
Preload (at starting):
Add driven pinion preload 0.5 - 0.9 kg (1.1 - 2.0 lb, 4.9 - 8.8 N)
NOTE: Turn the drive pinion counterclockwise and clockwise several times.
d. Adjust the total preload by tightening the adjusting nut with SST.
SST 09318-12010
NOTE: Measure the preload while tightening the bearing adjusting nut a little at a time.
5. CHECK RING GEAR BACKLASH
a. Using a dial indicator, measure the ring gear backlash.
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 in.)
b. When the backlash is outside the standard value, select a different plate washer to the one selected in step 3. Again adjust the backlash and total preload.
6. CHECK TOOTH CONTACT
a. Coat 3 or 4 teeth at four different positions on the ring gear with red lead.
b. Rotate the ring gear, inspect the teeth pattern.
c. If the teeth are not connecting properly, select a different shim and plate washer.
7. REMOVE TRANSFER RIGHT CASE
Remove the ten bolts and transfer right case.
8. REMOVE RING GEAR MOUNTING CASE AND CENTER DIFFERENTIAL CASE
9. REMOVE DRIVEN PINION BEARING CAGE ASSEMBLY
Remove the six bolts and driven pinion bearing cage assembly.
10. REMOVE DIFFERENTIAL LEFT SIDE BEARING OUTER RACE AND PLATE WASHER
Using SST, remove the outer race and plate washer.
SST 09308-00010
11. INSTALL OIL SEAL
a. Using SST, install a new oil seal as shown.
SST 09316-60010 (09316-00010, 09316-00030)
Oil seal depth: 3 mm (0.12 in.)
b. Coat the lip of oil seal with MP grease.
12. INSTALL LEFT CASE BEARING OUTER RACE
a. Install the plate washer. (previously selected)
b. Using SST and a press, press in the outer race.
SST 09316-60010 (09316-00010, 09316-00060)
13. INSTALL DRIVEN PINION BEARING CAGE ASSEMBLY
a. Coat the O-ring with gear oil, and install it to the bearing cage assembly.
b. Install the bearing cage with adjust shim (Previously selected) to the transfer left case.
c. Install and torque the six bolts.
Torque: 400 kg.cm. (29 ft.lb., 39 N.m)
14. INSTALL RING GEAR MOUNTING CASE AND CENTER DIFFERENTIAL CASE
15. INSTALL TRANSFER RIGHT CASE
a. Install a new apply gasket to the left case.
b. Coat the O-ring with gear oil.
c. Install the O-ring to the oil pump strainer.
d. Install the oil pump strainer to the transfer right case.
e. Install and torque the bolt.
Torque: 55 kg.cm. (48 in.lb., 5.4 N.m)
f. Install the oil pump driven gear.
g. Remove any packing material and be careful not to drop oil on the contacting surfaces of the transfer left case or right case.
h. Apply seal packing to the left case as shown in the figure.
Seal packing: Part No.08826-00090 THREE BOND 1281 or equivalent
NOTE: Install the right case as soon as the seal packing is applied.
i. Install the right case to the left case.
j. Install and torque the ten bolts.
NOTE: Each bolt length (mm (in.)) is indicated in the figure.
Torque: 450 kg.cm. (33 ft.lb., 44 N.m)
16. CHECK TOTAL PRELOAD
17. INSTALL ADJUSTING NUT LOCK PLATE
a. Install the lock plate so that the projection from the lock plate fits properly into the groove of the adjusting nut.
NOTE: When the lock plate cannot be installed, tighten the adjusting nut the smallest amount possible.
b. Coat a new O-ring with gear oil and install it to the lock bolt.
c. Install and torque the lock bolt.
Torque: 73 kg.cm. (63 in.lb., 7 N.m)
18. INSTALL TRANSFER INSPECTION HOLE COVER
a. Apply seal packing to the left case as shown in the figure.
Seal packing: Part No.08826-00090 THREE BOND 1281 or equivalent
NOTE: Install the cover as soon as the seal packing is applied.
b. Install the hole cover to the transfer left case.
c. Install and torque the three bolts.
Torque: 160 kg.cm. (12 ft.lb., 16 N.m)
19. INSTALL TRANSFER RIGHT CASE RETAINER
a. Coat a new O-ring with gear oil, and install it and new apply gasket.
b. Install the right case retainer to the transfer right case.
c. Install and torque the five bolts
Torque: 300 kg.cm. (22 ft.lb., 29 N.m)
20. INSTALL EXTENSION HOUSING
a. Using SST and a hammer, drive in a new oil seal as shown.
SST 09325-20010
b. Coat the lip of the oil seal with MP grease.
c. Coat a new O-ring with gear oil and install it to the extension housing.
d. Install the extension housing to the driven pinion bearing cage.
e. Install and torque the four bolts.
Torque: 260 kg.cm. (19 ft.lb., 25 N.m)
f. Using a plastic hammer, install the dust deflector.
21. INSTALL DYNAMIC DAMPER
Install and torque the four bolts.
Torque: 260 kg.cm. (19 ft.lb., 25 N.m)
22. INSTALL REAR WHEEL SPEED SENSOR
a. Install a new O-ring to the speed sensor.
b. Install the speed sensor to the transfer left case.
c. Install and torque a bolt.
Torque: 55 kg.cm. (48 in.lb., 5.4 N.m)
23. INSTALL TRANSFER MODE SELECT LEVER AND ROD
a. Install the lever, rod and lever guide.
b. Install and torque the two bolts.
Torque:
a. 55 kg.cm. (48 in.lb., 5.4 N.m)
b. 115 kg.cm. (8 ft.lb., 11 N.m)
c. Install the bolt while setting the lever as shown.
Torque: 115 kg.cm. (8 ft.lb., 11 N.m)