Part 1

Rear Output Shaft Sub-assembly:

Input Shaft Sub-assembly:

Driven Sprocket Sub-assembly:

Low Planetary Gear Assembly:

TRANSFER ASSY OVERHAUL

HINT:
COMPONENTS: See Diagrams; Exploded Views.

1. DRAIN TRANSFER OIL
2. REMOVE TRANSFER CASE LOWER PROTECTOR





a. Remove the 4 bolts and transfer case lower protector.
3. REMOVE AUTOMATIC TRANSMISSION ASSY
4. REMOVE TRANSFER ASSY





a. Remove the 8 bolts and 2 clamps from the transmission.
5. REMOVE HOSES





a. Remove a actuator motor breather hose.
6. REMOVE SWITCH





a. Remove the indicator No.1 and No.2 switches, case No.1 plug and gaskets.
7. REMOVE TRANSFER GEAR SHIFT HEAD NO.2





a. Using a pin punch and hammer, remove the slotted pin from the gear shift head No.2.
8. REMOVE TRANSFER RH BEARING RETAINER SUB-ASSY





a. Remove the 5 bolts and the bearing retainer sub-assy.

HINT: If necessary, tap the extension housing with a plastic hammer to remove it.

9. REMOVE TRANSFER COVER TYPE T OIL SEAL
a. Using a screwdriver and hammer, remove the oil seal from the bearing retainer sub-assy.
10. REMOVE TRANSFER CASE COVER SUB-ASSY





a. Remove the 4 bolts and case cover sub-assy.
11. REMOVE BREATHER OIL DEFLECTOR
12. REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSY





a. Using a chisel and hammer, loosen the staked part of the output shaft companion flange lock nut.(front)
b. Using SST to hold the output shaft companion flange, remove the output shaft companion flange lock nut.(front)
SST 09330-00021





c. Using SST, remove the output shaft companion flange sub-assy.(front)
SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04051, 09957-04010, 09958-04011)
13. REMOVE TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL
a. Using a screwdriver and hammer, remove the oil seal from the output shaft companion flange sub- assy.(front)
14. REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSY
a. Remove the rear output shaft companion flange sub-assy in the same way as the front output shaft companion flange sub-assy.(rear)
SST 09330-00021, 09950-00011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04051, 09957-04010, 09958-04011)
15. REMOVE TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL
a. Using a screwdriver and hammer, remove the oil seal from the rear output shaft companion flange sum assy.(rear)
16. REMOVE EXTENSION HOUSING ASSY





a. Remove the 5 bolts and extension housing assy.

HINT: If necessary, tap the extension housing assy rear with a plastic hammer to remove it.

17. REMOVE TRANSFER EXTENSION HOUSING TYPE T OIL SEAL
a. Using a screwdriver and hammer, remove the oil seal.
18. REMOVE TRANSFER OUTPUT WASHER





a. Remove the 2 output washer and caller.
19. REMOVE TRANSFER CASE REAR





a. Remove the 12 bolts and 2 clamps.
b. Remove the transfer case rear.

HINT: If necessary, tap the transfer case rear with a plastic hammer to remove it.

20. REMOVE 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 CTR DIFFERENTIAL LOCK FORK SUB-ASSY W/FRONT DRIVE CLUTCH SLEEVE





a. Using 2 screwdrivers and a hammer, tap out the snap ring.





b. Remove the bolt, CTR differential lock fork sub-assy and front drive clutch sleeve.
22. REMOVE REAR OUTPUT SHAFT SUB-ASSY, FRONT DRIVE CHAIN AND DRIVEN SPROCKET SUB-ASSY





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-assy together with front drive chain and driven sprocket sub-assy.





d. Remove the rear output shaft sub-assy, front drive chain and driven sprocket sub-assy.
23. REMOVE TRANSFER DRIVEN SPROCKET BEARING





a. Using a press, remove the driven sprocket bearing.
24. REMOVE TRANSFER INPUT GEAR RADIAL BALL BEARING





a. Using SST, a press and steel bar, remove the transfer input gear radial ball bearing.
SST 09555-55010
25. REMOVE TRANSFER SHIFT ACTUATOR ASSY





a. Using 2 screwdrivers and a hammer, tap out the snap ring.





b. Remove the 3 bolts and transfer shift actuator assy.
26. REMOVE TRANSFER CASE NO.1 PLUG
a. Remove the transfer case plug No.1 (filler plug) and gasket.
27. REMOVE TRANSFER CASE NO.1 PLUG
a. Remove the transfer case plug No.1 (drain plug) and gasket.
28. REMOVE TRANSFER OIL SEPARATOR SUB-ASSY





a. Remove the 3 bolts and oil separator sub-assy.
29. REMOVE TRANSFER CASE MAGNET
30. REMOVE TRANSFER OIL PUMP BODY SUB-ASSY





a. Remove the 3 bolts and oil pump body sub-assy.
31. REMOVE TRANSFER OIL PUMP BODY D-RING





a. Using a screwdriver, remove the oil pump body O-ring.





32. REMOVE TRANSFER OIL PUMP GEAR
33. REMOVE LOW PLANETARY GEAR ASSY W/INPUT SHAFT SUB-ASSY





a. Using a snap ring expander, remove the snap ring.





b. Remove the low planetary gear assy and input shaft sum assy.





34. REMOVE TRANSFER OUTPUT SHAFT SPACER
35. REMOVE TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING
36. REMOVE TRANSFER CASE OIL SEAL
a. Using a screwdriver and hammer, remove the transfer case oil seal (No.1).
b. Using a screwdriver and hammer, remove the transfer case oil seal (No.2).
37. REMOVE TRANSFER INPUT GEAR STOPPER SHAFT SNAP RING





a. Using a snap ring expander, remove the input gear stopper shaft snap ring.





38. REMOVE TRANSFER INPUT GEAR STOPPER
39. REMOVE TRANSFER INPUT GEAR STOPPER BALL
40. REMOVE MANUAL TRANSFER PLANETARY CAR WASHER





41. REMOVE TRANSFER INPUT SHAFT
42. REMOVE TRANSFER THRUST BEARING RACE NO.1
43. REMOVE TRANSFER LOW PLANETARY GEAR BEARING





44. REMOVE TRANSFER INPUT SHAFT SEAL RING NO.1
45. INSPECT TRANSFER INPUT SHAFT





a. Using a micrometer, measure the outer diameter of the input shaft journal surface.
Minimum diameter: 47.59 mm (1.8736 inch)
If the outer diameter is less than the minimum, replace the input shaft.





b. Using a dial indicator, measure the inside diameter of the input shaft bushing.
Maximum diameter: 48.14 mm (1.8953 inch)
If the inside diameter exceeds the maximum, replace the input shaft.
46. INSPECT PLANETARY PINION GEAR THRUST CLEARANCE





a. Using a feeler gauge, measure the thrust clearance of the planetary pinion gear.
Standard clearance: 0.11 - 0.84 mm (0.0043 - 0.0331 inch)
Maximum clearance: 0.84 mm (0.0331 inch)
If the clearance exceeds the maximum, replace the planetary gear assy.
47. INSPECT PLANETARY PINION GEAR RADIAL CLEARANCE





a. Using a dial indicator, measure the radial clearance of the planetary pinion gear.
Standard clearance: 0.009 - 0.038 mm (0.0004 - 0.0015 inch)
Maximum clearance: 0.038 mm (0.0015 inch)
If the clearance exceeds the maximum, replace the planetary gear assy.
48. REMOVE TRANSFER INPUT SHAFT BEARING





a. Using a snap ring expander, remove the snap ring.
b. Using SST and a press, remove the input shaft bearing.
SST 09554-30011, 09555-55010
49. REMOVE TRANSFER LOW PLANETARY GEAR SPLINE PIECE





a. Using a screwdriver, remove the snap ring.
b. Remove the low planetary gear spline piece.
50. REMOVE TRANSFER LOW PLANETARY GEAR BEARING





a. Using SST, remove the low planetary gear bearing.
SST 09612-65014 (09612-01030, 09612-01050)

NOTICE: Hang SST securely to the clearance between the bearing and low planetary gear.

51. INSPECT DRIVE SPROCKET THRUST CLEARANCE





a. Using a feeler gauge, measure the thrust clearance of the drive sprocket.
Standard clearance: 0.15 - 0.24 mm (0.0059 - 0.0094 inch)
Maximum clearance: 0.24 mm (0.0094 inch)
If the clearance exceeds the maximum, replace the drive sprocket.
52. INSPECT DRIVE SPROCKET RADIAL CLEARANCE





a. Using a dial indicator, measure the radial clearance of the drive sprocket.
Standard clearance: 0.01 - 0.06 mm (0.0004 - 0.0024 inch)
Maximum clearance: 0.06 mm (0.0024 inch)
If the clearance exceeds the maximum, replace the drive sprocket, output shaft rear or needle roller bearing.
53. REMOVE TRANSFER LOW PLANETARY RING GEAR HOLE SNAP RING





a. Using a snap ring expander, remove the snap ring.
54. REMOVE TRANSFER OUTPUT SHAFT SPACER NO.2
55. REMOVE TRANSFER OUTPUT SHAFT SPACER BALL
56. REMOVE CENTER DIFFERENTIAL CASE





57. REMOVE TRANSFER CLUTCH HUB
58. REMOVE TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING
59. REMOVE TRANSFER OUTPUT SHAFT PLATE WASHER
60. REMOVE TRANSFER OUTPUT SHAFT REAR RADIAL BALL BEARING





a. Using SST and a press, remove the output shaft rear radial ball bearing.
SST 09555-55010





61. REMOVE TRANSFER OUTPUT SHAFT SPACER NO.1
62. REMOVE TRANSFER DRIVE SPROCKET SUB-ASSY
63. REMOVE TRANSFER DRIVE SPROCKET BEARING
64. REMOVE TRANSFER OUTPUT SHAFT PLATE WASHER
65. INSPECT TRANSFER OUTPUT SHAFT REAR





a. Using a micrometer, measure the outer diameter of the output shaft rear journal surface.
Standard diameter:
Part A: 27.98 - 27.99 mm (1.1016 - 1.1020 inch)
Part B: 31.98 - 32.00 mm (1.2591 - 1.2598 inch)
Part C: 34.98 - 35.00 mm (1.3772 - 1.3780 inch)
Part D: 36.98 - 37.00 mm (1.4559 - 1.4567 inch)
Minimum Diameter:
Part A: 27.98 mm (1.1016 inch)
Part B: 31.98 mm (1.2591 inch)
Part C: 34.98 mm (1.3772 inch)
Part D: 36.98 mm (1.4559 inch)
If the outer diameter is less than the minimum, replace the out put shaft rear
66. INSPECT HIGH AND LOW CLUTCH SLEEVE AND GEAR SHIFT FORK NO.2 CLEARANCE





a. Using vernier calipers, measure the thickness of the gear shift fork No.2 claw
Thickness: 10 mm (0.3937 inch)
b. Using vernier calipers, measure the groove of the high and low clutch sleeve
Distance: 10.5 mm (0.4134 inch)
c. Calculate a clearance between the high and low clutch sleeve and gear shift fork No 2 clearance.
Standard clearance: 0.26 - 0.84 mm (0.0102 - 0.0331 inch)
Maximum clearance: 0.84 mm (0.0331 inch)
If the clearance exceeds the maximum, replace the high and low clutch sleeve or gear shift fork No.2.
67. INSPECT FRONT DRIVE CLUTCH SLEEVE AND CTR DIFFERENTIAL LOCK FORK SUB-ASSY CLEARANCE





a. Using vernier calipers, measure the thickness of the CTR differential lock fork claw
Thickness: 10 mm (0.397 inch)
b. Using vernier calipers, measure the groove of the front drive clutch sleeve
Distance: 10.5 mm (0.4134 inch)
c. Calculate a clearance between the front drive clutch sleeve and CTR differential lock fork
Standard clearance: 0.26 - 0.84 mm (0.0102 - 0.0331 inch)
Maximum clearance: 0.84 mm (0.0331 inch)
If the clearance exceeds the maximum, replace the front drive clutch sleeve or CTR differential lock fork.
68. INSPECT CENTER DIFFERENTIAL CASE AND HIGH AND LOW CLUTCH SLEEVE





a. Check that the tip of the spline gear of the high and low clutch sleeve is not worn.
b. Install the high and low clutch sleeve to the center differential case and check that the high and low clutch sleeve moves smoothly.
69. INSPECT CENTER DIFFERENTIAL CASE AND FRONT DRIVE CLUTCH SLEEVE





a. Check that the tip of the spline gear of the front drive clutch sleeve is not worn.
b. Install the front drive clutch sleeve to the center differential case and check that the front drive clutch sleeve moves smoothly.