Disassembly of Transfer Component Parts

1. REMOVE TRANSFER VACUUM ACTUATOR
a. Remove the four bolts.
b. Remove the actuator bracket and stiffener center plate.




c. Remove the three bolts.
d. Remove the vacuum actuator.




2. REMOVE DUST BOOT




3. REMOVE DIFFERENTIAL LOCK SHIFT FORK SHAFT
a. Remove transfer indicator switch.
b. Using SST, remove the plug.
SST 09313-30021




c. Using SST, remove the plug.
SST 09043-38100




d. Remove the set bolt.
e. Remove the shift fork shaft, shift fork and sleeve.




4. REMOVE DINAMIC DAMPER
Remove the four bolts and dinamic danper.




5. REMOVE EXTENSION HOUSING
a. Remove the four bolts and tap off the housing with a plastic hammer.
b. Remove the O-ring and the dust deflector from the extension housing.




6. REMOVE SIDE GEAR SHAFT HOLDER
a. Using a screwdriver and hammer, remove the oil seal.




b. Using snap ring pliers, remove the snap ring.




c. Remove the shaft holder.




7. CHECK PRELOAD
a. Using SST and a spring tension gauge, measure the driven pinion preload of the backlash between the driven pinion and ring gear.
SST 09326-20011
Preload (at starting): 0.9 - 1,4 kg (2 - 3 lb, 9 - 14 N)
b. 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 (1 - 2 lb, 5 - 9 N)




8. REMOVE TRANSFER INSPECTION HOLE COVER
Remove the three bolts and a cover.




9. CHECK RING GEAR BACKLASH
Using a dial indicator, measure the ring gear backlash.
Backlash: 0.13-0.18 mm (0.0051 - 0.0071 in.)

10. CHECK TOOTH CONTACT
(See "Assembly of Transfer Component Parts")




11. REMOVE DRIVEN PINION BEARING CAGE ASSEMBLY
a. Remove the six bolts and tap off a plastic hammer.
b. Remove the O-ring and shim from the driven pinion bearing cage.




12. REMOVE TRANSFER RIGHT CASE
Remove the ten bolts and tap off the case with a plastic hammer.




13. REMOVE RING GEAR MOUTING CASE ASSEMBLY




14. REMOVE ADJUSTING NUT LOCK PLATE
Using snap ring pliers, remove the lock plate from the transfer right case.




15. IF NECESSARY, REPLACE EXTENSION HOUSING OIL SEAL
a. Using a screwdriver, remove the oil seal.




b. Using SST and a hammer, drive in a new oil seal.
SST 09325-20010
Oil seal depth: 1.1 - 1.9 mm (0.043 - 0.075 in.)
c. Coat the lip of oil seal with MP grease.




16. IF NECESSARY, REPLACE SHIFT FORK SHAFT OIL SEAL
a. Using a screwdriver and hammer, remove the oil seal.




b. Coat the lip of oil seal with MP grease.
c. Using a socket wrench and hammer, drive in a new oil seal as shown.
Oil seal height: 7.5 - 8.5 mm (0.295 - 0.335 in.)




17. IF NECESSARY, REPLACE SIDE GEAR SHAFT HOLDER BEARING
a. Using snap ring pliers, remove the snap ring.




b. Using a press, remove the bearing from the side gear shaft holder.




c. Using SST and a press, install a new bearing as shown.
SST 09316-60010 (09316-00010)




d. Using snap ring pliers, install the snap ring.




18. IF NECESSARY, REPLACE TRANSFER OIL TUBE
a. Remove the bolt and oil tube.




b. Using a screwdriver, remove the cushion.




c. Install a new cushion.




d. Install the oil tube.
e. Install and torque the bolt.
Torque. 130 kg-cm (9 ft-lb, 13 N.m)




19. IF NECESSARY, REPLACE RING GEAR MOUNTING CASE SIDE BEARING OUTER RACE (Transfer Right Case)
a. Using SST, turn the bearing adjusting nut, remove the outer race and bearing adjusting nut.
SST 09318-20010




b. Install the bearing adjusting nut until it touches the lip of the case.

HINT: If the nut is difficult to turn, use SST (09318- 20010).




c. Using SST and a press, install the press until it is almost touching the bearing adjusting nut.
SST 09608-35014 (09608-06020, 09608-06160)




(Transfer Left Case)
a. Using a brass ber and hammer, drive out the bearing outer race lightly and evenly.
b. Remove the plate washer.




c. Install the plate washer.

HINT: First install a washer of the same thickness as before.




d. Using SST and a press, install the outer race.
SST 09316-60010 (09316-00010, 09316-00060)




20. MEASURE CLEARANCE OF DIFFERENTIAL LOCK SHIFT FORK AND SLEEVE
Measure the clearance between the shift fork and sleeve.
Maximum clearance: 1.0 mm (0.039 in.)




21. INSPECT TRANSFER VACUUM ACTUATOR
a. Apply a vacuum of 500 mmHg to port Z. Move out the push rod.
b. Apply a vacuum of 500 mmHg to port Y1 and Y2. Move in the push rod and measure the push rod strake.
Push rod strake: 16.5 mm (0.650 in.) or more
c. Apply a vacuum of 500 mmHg to port Y3. Check that no remain the vacuum in actuator.
If not, replace the actuator.
d. After the check, apply a vacuum of 500 mmHg to port Y of the actuator (Put the differential lock on the free side).