Removal and Installation

Removal

NOTE: Make sure the lifts, jacks, and safety stands are placed properly.

1. Raise the front of the vehicle, and support it with safety stands.
2. Set the parking brake, and block both rear wheels securely.
3. Drain the manual transmission fluid. Reinstall the drain plug with a new sealing washer.





4. Make reference marks (A) across the propeller shaft (B) and the companion flanges (C).
5. Separate the propeller shaft from the transfer assembly.





6. Remove the transfer assembly (A), dowel pin (B), and O-ring (C).

Installation

NOTE:
^ While installing the transfer assembly on the transmission, do not allow dust or other foreign particles to enter the transmission.
^ Be careful not to damage the clutch housing with transfer driven gear.

1. Install a new O-ring (A) on the transfer assembly (B), then install the dowel pin (C) on the transmission.





2. Apply MTF to the transfer driven gear and transmission contact area, then install the transfer assembly on the transmission.





3. Install the propeller shaft on the transfer assembly by aligning the reference marks.
4. Refill the transmission with MTF.
5. Start the engine, and run it to normal operating temperature (the radiator fan comes on). Turn the engine off, and check the fluid level.

Inspection
Transfer Gear (Hypoid gear) Backlash Measurement





1. Set a dial indicator (A) on the companion flange (B) as shown.
2. Measure the transfer gear backlash.
STANDARD: 0.06 - 0.16 mm (0.002 - 0.006 inch)

Total Starting Torque Measurement
3. Rotate the companion flange several times to seat the tapered roller bearing.





4. Measure the starting torque (companion flange side) using a torque wrench.

NOTE: To prevent damage to the transfer housing, always use soft jaws or equivalent materials between the transfer housing and the vise.

STANDARD:
2.24 - 3.71 Nm (22.0 - 36.4 kgf-cm, 19.1 - 31.6 inch lbs.)

Transfer Drive Gear Tooth Contact Inspection
5. Remove the transfer from the vise.





6. Remove the transfer holder assembly (A) from the transfer housing (B), then remove the dowel pin (C) and O-ring (D).
7. Apply Prussian Blue to the transfer drive gear teeth lightly and evenly.
8. Install the transfer holder assembly to the transfer housing, then tighten the bolts.
9. Rotate the companion flange in both directions until the transfer gear rotates one full turn in both directions.





10. Check the transfer gear tooth contact pattern.
11. If the measurements or the tooth contact pattern are not within the standard, disassemble the transfer assembly, replace worn or damaged parts, and reassemble it.