Repair Procedure - Steps 1 Thru 27
Verify that there is an oil leak from the transfer case. Proceed to remove the transfer case and replace the 0-ring using the following procedure.
1. Drain the transfer oil.
2. Remove the transfer case lower protector by removing the 4 bolts.
3. Remove the automatic transmission assembly.
Refer to the Technical Information System (TIS), 2003 or 2004 model year GX 470 Repair Manual: Automatic Transmission / Trans: Automatic Transmission Assy: Replacement.
4. Remove the transfer assembly. Remove the 8 bolts and 2 clamps from the transmission.
5. Remove the actuator motor breather hoses.
6. Remove the switches. Remove the indicator No.1 and No.2 switches, case No. 1 plug, and gaskets.
7. Remove the transfer gear shift head No.2.
Using a pin punch and hammer, remove the slotted pin from the gear shift head No. 2.
8. Remove the transfer RH bearing retainer sub-assembly by removing the 5 bolts.
HINT:
If necessary, tap the extension housing with a plastic hammer to remove it.
9. Remove the transfer cover type T oil seal.
Using a screwdriver and hammer, remove the oil seal from the bearing retainer sub-assembly.
10. Remove the transfer case cover sub-assembly by removing the 4 bolts.
11. Remove the breather oil deflector.
12. Remove the front output shaft companion flange sub-assembly.
A. Using a chisel and hammer, loosen the staked part of the output shaft companion flange lock nut.
B. Using the SST to hold the output shaft companion flange, remove the output shaft companion flange lock nut.
^ SST P/N 09330-00021
C. Using the SSTs, remove the front output shaft companion flange sub-assembly.
^ SST P/N 09950-40011-02
(09951-04020, 09952-04010,
09953-04030, 09954-04010,
09955-04051, 09957-04010,
09958-04011)
13. Remove the front transfer output shaft companion flange oil seal.
Using a screwdriver and hammer, remove the oil seal from the output shaft companion flange sub-assembly.
14. Remove the rear output shaft companion flange sub-assembly in the same way as the front output shaft companion flange sub-assembly (step 12).
15. Remove the rear transfer output shaft companion flange oil seal.
Using a screwdriver and hammer remove the oil seal from the rear output shaft companion flange sub-assembly.
16. Remove the extension housing assembly by removing the 5 bolts.
HINT:
If necessary, tap the extension housing assembly rear with a plastic hammer to remove it.
17. Remove the transfer extension housing type T oil seal.
Using a screwdriver and hammer, remove the oil seal.
18. Remove the 2 transfer output washers and collar.
19. Remove the transfer case rear by removing the 12 bolts and 2 clamps.
HINT:
If necessary, tap the transfer case rear with a plastic hammer to remove it.
20. Remove the transfer gear shift fork No. 2 w/transfer high and low clutch sleeve.
A. Using a hexagon wrench, remove the plug No. 1.
B. Using a magnetic finger, remove the spring and ball from the hole.
C. Using a pin punch and hammer, drive out the slotted spring pin.
D. Remove the gear shift fork No. 2 and high and low shift fork shaft.
E. Remove the high and low clutch sleeve.
21. Remove the center differential lock fork sub-assembly w/front drive clutch sleeve.
A. Using 2 screwdrivers and a hammer, tap out the snap ring.
B. Remove the bolt, center differential lock fork sub-assembly, and front drive clutch sleeve.
22. Remove the rear output shaft sub-assembly, front drive chain, and driven sprocket sub-assembly.
A. Using a snap ring expander, remove the snap ring.
B. Mount the transfer case rear in a vise.
C. Using a plastic hammer, carefully tap the transfer case rear, and remove the rear output shaft sub-assembly together with the front drive chain and the driven sprocket sub-assembly.
D. Remove the rear output shaft sub-assembly, front drive chain, and driven sprocket sub-assembly.
23. Remove the transfer shift actuator assembly.
A. Using 2 screwdrivers and a hammer, tap out the snap ring.
B. Remove the 3 bolts and the transfer shift actuator assembly.
24. Remove the old 0-ring on the transfer case actuator assembly.
25. Examine the transfer case actuator sealing surface and confirm the plastic is intact and NOT damaged. If the transfer case plastic IS damaged, replace the transfer case actuator.
26. Install the NEW 0-ring on the transfer case actuator.
27. Install the transfer case oil seal.
A. Using the SST (or equivalent tool) and a hammer, drive in a NEW oil seal until its surface is flush with the case upper surface (No. 1).
SST P/N 09316-60011 (09316-00011, or equivalent)
B. Coat the lip of the oil seal with CMP grease.
C. Using the SST (or equivalent tool) and a hammer, drive in a NEW oil seal until its surface is flush with the case upper surface (No. 2).
^ SST P/N 09304-12012
(or equivalent)
Oil seal drive in depth:
-0.5 to 0.5 mm (-0.020 to 0.020 in.)
D. Coat the lip of the oil seal with CMP grease.
E. Using a snap ring expander, install the snap ring.