Adjustment

RING GEAR SHAFT

Adjustment

Adjusting shim selection

Ring gear bearing adjusting shim (left)
1.Measure the dimensions of each measuring point with the following procedure:

- Measure dimension (A) of transfer case with a pair of vernier calipers. Refer to "Measuring point".

CAUTION:
Never damage transfer case.

- Measure the diameter (X) of transfer case with a pair of vernier calipers. Refer to "Measuring point".

CAUTION:
Never damage transfer case.

- Measure dimension (Y') of transfer case (including the thickness of straightedge) with a pair of vernier calipers and straightedge. Refer to "Measuring point".

CAUTION:
Never damage transfer case.

- Measure the thickness of straightedge.
- Calculate the dimension "Y" by formula below.

Y = Y' "Thickness of straightedge"

- Measure dimension (Z) of transfer case with a pair of vernier calipers and straightedge. Refer to "Measuring point".

CAUTION:
Never damage transfer case.

- Measure dimension (V) of ring gear shaft with a pair of vernier calipers. Refer to "Measuring point".

- Measure dimension (W) of ring gear shaft with a pair of vernier calipers. Refer to "Measuring point".

- Measure dimension (E) of ring gear shaft with a pair of vernier calipers. Refer to "Measuring point".

- Measure dimension (F) from outer race edge surface of ring gear bearing (left) to inner race edge surface with depth gauge. Refer to "Measuring point".

- Measure thickness (G) of spacer (left) with a pair of vernier calipers. Refer to "Measuring point".
2.Calculate dimension "B" by the formula below.

B = Z Y (X x 0.5)

3.Calculate dimension "D" by the formula below.

D = E V + W

4.Check dimension (M) on the ring gear side face.
NOTE:
Dimension "M" indicates the difference between the optimum engagement and standard dimensions in increments of 0.01 mm (0.0004 in) written on the ring gear side face.
5.Calculate the thickness of the ring gear bearing adjusting shim (left) "T
1" by the formula below.

T1 = A B + C + D E F G (M / 100) + 0.045 mm (0.0018 in)

NOTE:
Calculate dimension "C" as 56.0 mm (2.20 in)
6.Select ring gear bearing adjusting shim (left).
For selection adjusting shim, refer to the latest parts information.

CAUTION:
- Only one adjusting shim can be selected.
- Select the closest one, favoring thicker over thinner when necessary if no adjusting shim with the calculated value is available.
Ring gear bearing adjusting shim (right)
1.Measure the dimensions of each measuring point with the following procedure:

- Measure the diameter (X) of transfer case with a pair of vernier calipers. Refer to "Measuring point".

CAUTION:
Never damage transfer case.

- Measure the thickness of straightedge.
- Calculate the dimension "Y" by formula below.
Y = Y' "Thickness of straightedge"

- Measure dimension (Z) of transfer case with a pair of vernier calipers and straightedge. Refer to "Measuring point".

CAUTION:
Never damage transfer case.

- Measure dimension (H) from outer race edge surface of ring gear bearing (right) to inner race edge surface with depth gauge. Refer to "Measuring point".

- Measure thickness (I) of spacer (right) with a pair of vernier calipers. Refer to "Measuring point".
2.Calculate dimension "B" by the formula below.

B = Z Y (X x 0.5)

3.Calculate dimension "D" by the formula below.

D = E V + W

4.Check dimension (M) on the ring gear side face.
NOTE:
Dimension "M" indicates the difference between the optimum engagement and standard dimensions in increments of 0.01 mm (0.0004 in) written on the ring gear side face.
5.Calculate the thickness of the ring gear bearing adjusting shim (right) "T2" by the formula below.

T2 = B C D H I + (M / 100) + 0.045 mm (0.0018 in)

NOTE:
Calculate dimension "C" as 56.0 mm (2.20 in)

6.Select ring gear bearing adjusting shim (right).
For selection adjusting shim, refer to the latest parts information.

CAUTION:
- Only one adjusting shim can be selected.
- Select the closest one, favoring thicker over thinner when necessary if no adjusting shim with the calculated value is available.
Drive pinion adjusting shim
1.Measure the dimensions of each measuring point with the following procedure:

- Measure dimension (L) from outer race edge surface of pinion bearing (front) to inner race edge surface with depth gauge.
Refer to "Measuring point".

- Measure dimension (Q) of transfer case with depth gauge and straightedge. Refer to "Measuring point".

CAUTION:
Never damage transfer case.

- Measure dimension (R') of transfer case (including the thickness of straightedge) with a pair of vernier calipers and straightedge. Refer to "Measuring point".

CAUTION:
Never damage transfer case.

- Measure the thickness of straightedge.
- Calculate the dimension "R" by formula below.
R = R' "Thickness of straightedge"

- Measure the diameter (S) of transfer case with a pair of vernier calipers. Refer to "Measuring point".

CAUTION:
Never damage transfer case.
2.Calculate dimension "J" by the formula below.

J = R Q + (S x 0.5)

3.Check dimension (O) on the gear end of drive pinion.

NOTE:
Dimension "O" indicates the difference between the optimum engagement and the standard dimensions in increments of 0.01
mm (0.0004 in) written on the gear end of drive pinion.
4.Calculate the thickness of the drive pinion adjusting shim "T3" by the formula below.

T3 = J K L + (O / 100)

NOTE:
Calculate dimension "K" as 70.85 mm (2.7894 in)

5.Select drive pinion adjusting shim.
For selection adjusting shim, refer to the latest parts information.

CAUTION:
- Only one adjusting shim can be selected.
- Select the closest one, favoring thicker over thinner when necessary if no adjusting shim with the calculated value is available.

DRIVE PINION BEARING PRELOAD

1.Remove ring gear shaft assembly from the transfer case. Disassembly.
2.Rotate the companion flange back and forth from 2 to 3 times to check for unusual noise, binding, sticking, and so on.
3.Rotate the companion flange at least 20 times to check for smooth operation of the bearing.

4.Measure the drive pinion bearing preload with the preload gauge (A) [SST: ST-3127S000 (J-25765-A)].

Drive pinion bearing preload: Preload Torque.

CAUTION:
Each rotational part should rotate smoothly with the specified gear oil.
- If outside the standard, disassemble the drive pinion assembly to check and adjust each part.

TOTAL PRELOAD

1.Measure drive pinion bearing preload.

CAUTION:
Check that the drive pinion bearing preload is within the standard.
2.Assemble the ring gear shaft assembly to the transfer case. Assembly
3.Install transfer cover to check and adjust each part. Assembly.

CAUTION:
Never apply liquid gasket.
4.Rotate the companion flange at least 20 times to check for smooth operation of the bearing.

5.Measure the total preload with the preload gauge (A) [SST: ST-3127S000 (J-25765-A)].

Total preload:Preload Torque.

CAUTION:
Each rotational part should rotate smoothly with the specified gear oil.
- If outside the standard, disassemble the transfer assembly to check and adjust each part. Measure it with the transfer case oil seals removed when measuring total preload after disassembly. Then install transfer case oil seals.
6.Reinstall transfer cover for applying liquid gasket. Assembly.

BACKLASH

1.Install the bolt to the companion flange.

2.Fit a dial indicator onto the bolt (A).
3.Measure the circumference backlash of the companion flange.

Backlash: Backlash.

- If outside the standard, disassemble the transfer assembly to check and adjust each part.

TOOTH CONTACT

1.Remove transfer cover. Disassembly.
2.Remove ring gear shaft assembly from transfer case. Disassembly.

3.Apply red lead onto the ring gear.

CAUTION:
Apply red lead to both faces of 3 to 4 gears at 4 locations evenly spaced on the ring gear.
4.Assemble the ring gear shaft assembly to the transfer case.
Assembly.
5.Install transfer cover to check and adjust each part. Refer to
Assembly.

CAUTION:
Never apply liquid gasket.
6.Rotate the companion flange back and forth several times.
7.Remove ring gear shaft assembly from transfer case. Then check drive pinion to ring gear tooth contact

8.Follow the procedure below to adjust pinion height (dimension X) if tooth contact is improper. For selecting adjusting shim, refer to the latest parts information.

CAUTION:
If no adjusting shim with the calculated value is available, select the thicker and closest one.

- Thicken the drive pinion adjusting shim to move the drive pinion closer to the ring gear in case of face contact or heel contact.

CAUTION:
Only one adjusting shim can be selected.

- Thin the drive pinion adjusting shim to move the drive pinion farther from the ring gear in case of flank contact or toe contact.

CAUTION:
Only one adjusting shim can be selected.
9.Reinstall transfer cover for applying liquid gasket. Assembly.

COMPANION FLANGE RUNOUT

1.Fit a dial indicator onto the companion flange face (inner side of the propeller shaft bolt holes).
2.Rotate the companion flange to check for runout.

Companion flange runout: Companion Flange Runout.

3.Fit a test indicator to the inner side of the companion flange (socket diameter).
4.Rotate the companion flange to check for runout.

Companion flange runout: Companion Flange Runout.

5.Follow the procedure below to adjust if runout value is outside the repair limit.

CAUTION:
Replace collapsible spacer to check and adjust each part when companion flange is adjusted or replaced.
a.Check for runout while changing the phase between companion flange and drive pinion in 90� steps. Then search for the minimum point.
b.Replace companion flange if runout value is still outside the limit after the phase has been changed.
c.Adjust assembly status of the pinion bearings and drive pinion, or replace drive pinion bearings if runout is outside the standard after the companion flange is replaced.