Transfer Cover Assembly

Transfer Cover Assembly






Disassembly





1. Using a precision screwdriver or a suitable tool, push down the lock to unlatch the terminal for the coil assembly, and pull the terminal out.

Note: Use care to prevent damage to harness terminal and connector.





2. Remove the coil assembly set nuts (3 pieces) and coil assembly from the transfer cover.





3. Using snap ring pliers, remove the snap ring from the transfer cover.





4. Strike the speed gear and tone wheel with a rod or other appropriate tool from the rear side of the transfer cover assembly, and remove the ball bearing, speed gear and tone wheel.

Note: Use care to prevent damage to the speed gear teeth.





5. Using the bearing remover J-42805 and slide hammer J-2619-01, remove the ball bearing of the front output shaft from the transfer cover.

Reassembly
Transfer cover oil seal replacement
1. Remove the oil seal from the transfer cover assembly.
2. Apply oil to the circumference of the new oil seal and fill the lip with grease (BESCO L2 or its equivalent).





3. Using the oil seal installer J-42804, install the oil seal to the transfer cover assembly.
Shift shaft oil seal replacement
4. Remove the oil seal from the transfer cover assembly.
5. Apply oil the circumference of the new oil seal.





6. Using the oil seal installer J-33951, install the oil seal to the transfer cover assembly.
The drive in depth must be 9.4 - 10.4 mm (0.370 - 0.409 inch). The knurled end of the installer (indicated by the arrow) must be flush with the oil seal installation surface.

Note: Use care to prevent tilt to oil seal when installing oil seal to the case.

7. Install the ball bearing of the front output shaft to the transfer cover.
8. Install the speed gear and tone wheel.
9. Install the ball bearing to the transfer cover.





10. Using snap ring pliers, install the snap ring to the transfer cover.

Note: The snap ring must be fully inserted into the transfer cover snap ring groove.

11. Install the coil assembly to the transfer cover and tighten the set nuts (3 pieces) to the specified torque.
Torque: 10 Nm (87 inch lbs.)





12. Install the connector to the harness terminal of the coil assembly.