Transfer Rear Case Assembly (A/T)

Transfer Rear Case Assembly (A/T)








Removal
1. Remove the speedometer sensor (1).
2. Remove the plate (1).
3. Remove the speedometer driven gear bushing and driven gear (1).

Note: Apply a reference mark to the driven gear bushing before removal.





4. Remove front companion flange (2) and rear companion flange (3), using the flange companion holder J-8614-11 to remove the end nut.
5. Remove the front and rear companion flange.

Note: Use the universal puller to remove the rear companion flange.

6. Disconnect the actuator breather hose and transfer breather hose from control box (4).
7. Remove control box assembly (4).





8. Disconnect the actuator breather hose and 2WD-4WD actuator heat protector (5) from the 2WD-4WD actuator assembly (6).
9. Remove the 2WD-4WD actuator assembly bolts.








10. Pull the 2WD-4WD actuator assembly (6) with 2WD-4WD shift rod.





11. Off set the actuator assembly.





12. Remove the actuator assembly (6).
13. Remove transfer rear cover assembly (7) from transfer case assembly.

Installation





1. Apply the recommended liquid gasket (LOCTITE 17430) or its equivalent to the transfer rear cover fitting faces.
2. Install transfer rear cover assembly (7) to transfer case assembly (8).





3. Perform the following steps before fitting the transfer rear case.
1. Shift the high-low shift rod to the 4H side.
2. The cut-away portion of the select rod head (15) should align with that of the rear case hole's stopper (16).
4. Tighten the transfer rear case bolts to the specified torque.
Torque: 37 Nm (27 ft. lbs.)
5. Shift the 2WD 4WD shift rod (17) to the 4WD side.





6. Join the rod grooves of 2WD-4WD actuator assembly (6) and shift rod (17).





7. Push the 2WD-4WD actuator assembly (6) with 2WD-4WD shift rod (17) till the shift rod (17) reaches the 2WD position.
8. Tighten the 2WD-4WD actuator bolts to the specified torque.
Torque: 19 Nm (14 ft. lbs.)
9. Connect the actuator breather hose to actuator.
10. Install actuator heat protector (5).
11. Install control box assembly (4).
Torque: 19 Nm (14 ft. lbs.)
12. Connect breather hoses to control box (4).





13. Install rear companion flange (3) and front companion flange (2), using the companion flange holder J-8614-11 to tighten the flange nuts to the transfer case.
14. Tighten the new transfer flange nuts to the specified torque.
Torque
Rear companion flange: 167 Nm (123 ft. lbs.)
Front companion flange: 137 Nm (101 ft. lbs.)





15. Use the punch J-39209 to stake the rear companion flange nut (3) at two spots.





16. Stake the front companion flange nut (2) at one spot.

Note: Be sure to confirm that there is no crack at the staked portion of the flange nut after staking.

17. Install the O-ring (23) to the speedometer driven gear bushing (22).
18. Install the driven gear to the speedometer driven gear bushing (22).
19. Install the speedometer driven gear assembly to the transfer rear cover.
20. Install the plate (21) to the transfer rear case and tighten to the specified torque.
Torque: 15 Nm (11 ft. lbs.)





21. Install the speedometer sensor and tighten to the specified torque.
Torque: 27 Nm (20 ft. lbs.)