Transfer Case Reassembly

TRANSFER CASE

REASSEMBLY





NOTE:
1. Clean all parts except the taper roller bearings. Be careful about the direction of seals.
2. Oil bearings with hypoid gear oil API GL5.
3. Smear involute splines all covering with high pressure grease Klueber microlube GNY202.
4. Measuring temperature. 20° ± 5°C.
5. O-ring has to be dipped into hypoid gear oil API GL5. Allow excess oil to drain.
6. Contact surface of the transfer housing to be coated with SEALANT 732 or equivalent (silicon type sealing agent) prior to mounting.
Coating thickness: 0.1mm MIN. Prior to coating, mating surfaces must be clean and free from oil and grease.
7. Transfer oil specification: Hypoid gear oil API GL5, SAE 8OW190 SHELL SPIRAX AX EQUIVALENT. Filled up to lower filler plug thread level (Approximately 0.8L)
8. The hypoid gear set must be managed as a pair. Whenever installing or replacing a hypoid gear shaft assembly or a pinion shaft, make sure to install or replace as a pair.
9. In reassembling, refer to the two figures.

1. Install the transfer drive gear with the taper roller bearings into transfer housing.





2. Applying the preload (100 to 200 N) to bearings, measure the dimension J.





3. Measure the dimension H on transfer cover.
4. Select the spacer thickness from the chart.
Thickness S4= H-J+K. K Bearing preload = 0.07 to 0.11 mm.)
Corresponding preload torque (measured without seals): 120 to 180 Ncm.





5. Reassemble the selected spacer above.
6. Measure the dimension U and V.
U---. Finished dimension of transfer housing.
V---. Distance from back of the hypoid gear to bearing measured under 100 to 200 N preload.
7. Select the spacer thickness from the chart. Thickness S2=U-(V + mounting distance 52.0 mm).








8. Install the spacer selected above, the taper roller bearings and the hypoid gear shaft assembly. And preload the assembly without the spacer (Hypoid gear shaft assembly-Transfer cover side) with 100 to 200 N.
9. Measure the dimension L after 10 rotations.
10. Measure the dimension M on transfer cover.
11. Select the spacer thickness from the chart above in the step 7. Thickness S3 = M-L + (0.09 to 0.12 mm) preload.
12. Install the spacer selected above.
13. Install the taper roller bearing outer races to the transfer housing and cover.
14. Insert the inner drive shaft assembly into the transfer cover.





15. Fixing the inner drive shaft assembly with a snap ring (A), insert a new oil seal into the transfer cover.





16. Install a new oil seal (A) in the transfer housing.





17. Install the hypoid gear shaft assembly (A) in the transfer housing.





18. Install the transfer drive gear assembly (A) in the transfer housing.





19. Assemble the transfer cover (A) and inner drive shaft assembly (B) with the transfer housing assembly. Tighten the mounting bolts.
TORQUE: 36.3 - 39.2 Nm (370 - 400 kgf-cm, 14.5 - 21.7 ft. lbs.)
20. Measure the dimension F
F.... Assembled dimension of pinion assembly.
G... Finished dimension of transfer housing. (88.0 mm)
E... Mounting distance(-69.500 ± deviation).
21. Select the spacer thickness from the chart. Thickness S 1 =E+F-G

NOTE: If it is not possible to reach the exact mounting distance, select the next thinner spacer S1.








22. Install the pinion assembly with the selected spacer above and measure the circumference backlash on pinion.
(Measuring diameter, backlash and permissible deviations for measurement an pinion, refer to table).
If the result is out of permissible range, change the spacer thickness S2, then start again with the step 8-12).

TIPS FOR SPACER ADJUSTMENT FOR HYPOID GEAR BACKLASH AND CONTACT PATTERN

TIPS FOR SPACER ADJUSTMENT FOR HYPOID GEAR BACKLASH AND CONTACT PATTERN:

23. Remove the pinion assembly. With the spacer 83 and transfer cover mounted, combined preload torque for the hypoid gear shaft assembly and transfer gear (measured on transfer gear) should be 2.7 to 3.8 Nm. The spacer S3 has to be changed, if the preload torque is not within the permissible range.





24. Tighten the pinion assembly mounting bolts (6EA) to install the pinion assembly (A).
TORQUE: 36.3 - 39.2 Nm (370 - 400 kgf-cm, 14.5 - 21.7 ft. lbs.)

NOTE:
1. Before installing the pinion assembly, check the pinion O-ring and apply the oil to the O-ring.
2. To make the installation of the pinion to the transfer easier, tap the pinion using a plastic hammer after aligning the bolt holes.

25. Refill the transfer oil through the drain plug hole to the specification.
Transfer oil: API GL-5 or SAE 80W/90
Quantity: 0.8 Liters