Part 1
OVERHAUL1. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
2. REMOVE TRANSFER STIFFENER PLATE RH
3. REMOVE AUTOMATIC TRANSMISSION W/TRANSFER
4. REMOVE TRANSFER CASE NO.1 PLUG
a. Remove the transfer case No. 1 plug.
b. Remove the gasket No.1 from the transfer case No.1 plug.
5. REMOVE TRANSFER CASE NO.2 PLUG
a. Remove the transfer case No.2 plug.
b. Remove the gasket No.2 from the transfer case No.2 plug.
6. REMOVE TRANSFER DRAIN PLUG
a. Remove the transfer drain plug and bleed the oil.
b. Remove the drain gasket from the transfer drain plug.
7. REMOVE TRANSFER ASSEMBLY
a. Remove the 2 bolts and 6 nuts.
b. Using a plastic hammer, remove the transfer assembly from the transaxle assembly.
NOTICE:
^ Remove the transfer assembly from the transaxle assembly without tilting it.
^ When removing the transfer assembly, do not hold onto the oil seal parts on both sides of the assembly.
8. REMOVE TRANSFER COVER GASKET
a. Remove the transfer cover gasket from the transfer assembly.
9. REMOVE TRANSFER CASE BREATHER PLUG
a. Using a screwdriver and a hammer, remove the transfer case breather plug from the transfer case cover No.1.
NOTICE: Be careful not to damage the contact surface of the case cover No.1.
10. REMOVE TRANSFER CASE COVER NO.1
a. Remove the 8 bolts.
b. Using a brass bar and a hammer, remove the transfer case cover No.1 from the transfer case.
NOTICE: Be careful not to damage the contact surfaces of the case and cover.
11. REMOVE BREATHER OIL DEFLECTOR
a. Remove the bolt and breather oil deflector from the transfer case cover No.1.
12. REMOVE TRANSFER DYNAMIC DAMPER
a. Remove the 3 bolts and the transfer dynamic damper from the transfer extension housing sub-assembly.
13. REMOVE TRANSFER CASE STRAIGHT PIN
a. Remove the 4 transfer case straight pins from the transfer case.
14. REMOVE TRANSFER & TRANSAXLE SETTING STUD BOLT
a. Remove the 4 transfer & transaxle setting stud bolts.
15. FIX TRANSFER ASSEMBLY
a. Fix the transfer assembly to the overhaul attachment.
16. REMOVE TRANSFER EXTENSION HOUSING DUST DEFLECTOR
a. Using a plastic hammer, remove the transfer extension housing dust deflector from the transfer extension housing sub-assembly.
17. REMOVE TRANSFER EXTENSION HOUSING TYPE T OIL SEAL
a. Using SST(s), remove the transfer extension housing type T oil seal from the transfer extension housing.
SST 09308-00010
NOTICE: Be careful not to damage the oil-seal-fitted surface of the housing and the inside surface of the bush.
18. REMOVE TRANSFER EXTENSION HOUSING SUB-ASSEMBLY
a. Remove the 4 bolts.
b. Using a plastic hammer, remove the transfer extension housing sub-assembly from the transfer case.
19. INSPECT PRELOAD
a. Using SST(s) and a torque wrench, check the initial torque within the backlash range.
SST 09326-20011
Torque: 0.9 to 1.4 Nm (9 to 14 kgf-cm, 8.0 to 12.4 inch lbs.)
HINT: Use a torque wrench with a fulcrum length of 160 mm (6.30 inch)
b. Using SST(s) and a torque wrench, check the initial torque while the driven pinion is in contact with the ring gear face.
SST 09326-20011
Torque: Preload +0.15 to 030 Nm (+1.6 to 3.1 kgf-cm, +1.3 to 2.7 inch lbs.)
HINT: Use a torque wrench with a fulcrum length of 160 mm (6.30 inch)
20. INSPECT BACKLASH
a. Set the dial gauge perpendicular to the tooth face of the ring gear, fix the driven pinion and inspect the backlash while moving the gear.
Backlash: 0.10 to 0.15 mm (0.0039 to 0.0059 inch)
NOTICE: Inspect it at 3 points or more on the gear's periphery.
21. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVEN PINION
a. Apply red lead primer thinly and uniformly to both faces of the ring gear and rotate several times.
NOTICE: Inspect the tooth contact on the ring gear at 4 places or more.
b. Proper washer location is shown in the illustration.
22. REMOVE CTR DIFFERENTIAL LOCK SLEEVE
a. Using snap ring pliers, remove the shaft snap ring.
b. Using SST(s), remove the CTR differential lock sleeve.
SST 09308-00010
23. REMOVE O-RING
a. Using a screwdriver with the tip protected by vinyl tape, remove the O-ring from the CTR differential lock sleeve.
NOTICE: Be careful no to damage the lock sleeve's groove for the O-ring.
24. REMOVE TRANSFER CASE OIL SEAL
a. Using SST(s), remove the transfer case oil seal from the case.
SST 09308-00010
NOTICE: Be careful not to damage the oil-seal-fitted surface of the case.
25. REMOVE TRANSFER RH BEARING RETAINER OIL SEAL
a. Using SST(s), remove the transfer RH bearing retainer oil seal from the transfer RH bearing retainer sub-assembly.
SST 09308-00010
NOTICE: Be careful not to damage the oil-seal-fitted surface of the retainer.
26. REMOVE TRANSFER RH BEARING RETAINER SUB-ASSEMBLY
a. Remove the 7 bolts from the transfer RH bearing retainer sub-assembly.
b. Using a screwdriver and a hammer, create a clearance between the transfer RH bearing retainer sub-assembly and the transfer case.
NOTICE: Be careful not to damage the transfer RH bearing retainer sub-assembly and the transfer case.
c. Using SST(s), remove the transfer RH bearing retainer sub-assembly from the transfer case.
SST 09520-10021
27. REMOVE O-RING
a. Using a screwdriver with the tip protected by vinyl tape, remove the 2 O-rings from the transfer RH bearing retainer sub-assembly.
NOTICE: Be careful not to damage the retainer's grooves for the O-rings.
28. REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING
a. Fix the transfer RH bearing retainer sub-assembly in a vise.
b. Using SST(s), remove the center differential case tapered roller bearing RH outer race, transfer ring gear mounting case washer No.2 and right bearing retainer oil seal No.2 from the transfer RH bearing retainer sub-assembly.
SST 09308-00010
NOTICE: Be careful not to damage the oil-seal-fitted surface of the transfer RH bearing retainer sub-assembly.
29. REMOVE SIDE GEAR SHAFT HOLDER BEARING
a. Using snap ring pliers, remove the side gear shaft holder hole snap ring.
b. Remove the side gear shaft holder bearing from the transfer RH bearing retainer sub-assembly.
30. REMOVE TRANSFER RING GEAR MOUNTING CASE
a. Remove the transfer ring gear mounting case from the transfer case.
31. REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING
a. RH side: Using SST(s), remove the inner race of the center differential case tapered roller bearing from the transfer ring gear mounting case.
SST 09950-40011 (09951-04010, 09952-04010. 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00420)
NOTICE: Apply grease to the screw thread and tip of the SST(s) before use.
HINT: When the roller comes off due to deformation of the gauge, completely remove the roller and remaining inner races of the center differential case tapered roller bearing from the transfer ring gear mounting case.
SST 09950-00020, 09950-00030, 09950-60010 (09951-00430)
NOTICE: Apply grease to the screw thread and tip of the SST(s) before use.
b. LH side: Using SST(s), remove the inner race of the center differential case tapered roller bearing from the transfer ring gear mounting case.
SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00360)
NOTICE: Apply grease to the screw thread and tip of the SST(s) before use.
HINT: When the roller comes off due to deformation of the gauge, completely remove the roller and remaining inner races of the center differential case tapered roller bearing from the transfer ring gear mounting case.
SST 09950-00020, 09950-00030, 09950-60010 (09951-00360)
NOTICE: Apply grease to the screw thread and tip of the SST(s) before use.
32. REMOVE RING GEAR
a. Put matchmarks on the transfer ring gear mounting case and the ring gear.
b. Remove the 12 bolts.
c. Using a plastic hammer, remove the ring gear by tapping around its periphery.
NOTICE: Do not damage the teeth of the ring gear.
33. INSPECT RUNOUT OF TRANSFER RING GEAR MOUNTING CASE
a. Using a dial gauge check the transfer ring gear mounting case runout.
Maximum runout: 0.03 mm (0.0012 inch)
34. REMOVE DRIVEN PINION
a. Using SST(s) and a hammer, unstake the transfer gear nut.
SST 09930-00010
b. Using SST(s), remove the transfer gear nut.
SST 09326-20011, 09556-16030
c. Using a press, remove the driven pinion, transfer driven pinion rear bearing inner race and transfer pinion bearing spacer.
NOTICE:
^ Put shop cloths around to help prevent the driven pinion from being dropped.
^ Place something like wood blocks under the case to keep it level.
35. REMOVE TRANSFER DRIVEN PINION FRONT BEARING
a. Using SST(s) and a press, remove the transfer driven pinion front bearing inner race from the driven pinion.
SST 09950-00020
36. REMOVE TRANSFER DRIVEN PINION FRONT BEARING
a. Using a brass bar and a hammer, lightly strike the transfer driven pinion front bearing outer race at 2 points to remove it from the transfer case.
37. REMOVE TRANSFER OUTPUT WASHER
a. Remove the transfer output washer from the transfer case.
38. REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING
a. Using a brass bar and a hammer, lightly strike the center differential case tapered roller bearing LH outer race at 2 points to remove it from the transfer case.
39. REMOVE RING GEAR MOUNTING CASE PLATE WASHER
a. Remove the ring gear mounting case plate washer from the transfer case.
40. REMOVE TRANSFER DRIVEN PINION REAR BEARING
a. Using a brass bar and a hammer, lightly strike the transfer driven pinion rear bearing outer race at 2 points to remove it from the transfer case.
41. INSTALL TRANSFER DRIVEN PINION REAR BEARING
a. Using SST(s) and a press, install the transfer driven pinion rear bearing outer race to the transfer case.
SST 09950-60010 (09951-00620), 09950-70010 (09951-07150)
NOTICE: Place something like wood blocks under the case to keep its level.
42. INSTALL TRANSFER OUTPUT WASHER
a. Install the transfer output washer to the transfer case.
HINT: Reuse the washer.
43. INSTALL TRANSFER DRIVEN PINION FRONT BEARING
a. Install the transfer driven pinion front bearing outer race to the transfer case with SST(s), bolt and nut.
SST 09950-60020 (09951-00750, 09951-00770, 09951-00810), 09316-60011 (09316-00061)
44. INSTALL RING GEAR MOUNTING CASE PLATE WASHER
a. Install the ring gear mounting case plate washer to the transfer case.
HINT: Reuse the washer.
45. INSTALL CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING
a. Using SST(s) and a press, install the center differential case tapered roller bearing LH outer race to the transfer case.
SST 09950-70010 (09951-07200), 09316-60011 (09316-00021)
46. INSTALL TRANSFER DRIVEN PINION FRONT BEARING
a. Using SST(s) and a press, install the transfer driven pinion front bearing inner race to the driven pinion.
SST 09316-60011 (09316-00041)
47. INSTALL DRIVEN PINION
a. Install the driven pinion to the transfer case.
b. Install a new transfer pinion bearing spacer and a new transfer driven pinion rear bearing inner race to the driven pinion.
c. Using SST(s), tighten a new transfer gear nut (at a standard torque.)
SST 09326-20011, 09556-16030
Torque: 277 to 378 Nm (2,820 to 3,855 kgf-cm, 204 to 279 ft. lbs.)
NOTICE: Do not stake the transfer gear nut.
HINT: Use a torque wrench with a fulcrum length of 750 mm (29.53 inch)
48. INSPECT AND ADJUST DRIVEN PINION PRELOAD
a. Using SST(s) and a torque wrench, measure the initial torque of the driven pinion.
Preload (at starting):
New bearing: 1.1 to 1.6 Nm (11 to 16 kgf-cm, 9.7 to 14.2 inch lbs.)
Used bearing: 0.9 to 1.4 Nm (9 to 14 kgf-cm, 8.0 to 12.4 inch lbs.)
HINT: Use a torque wrench with a fulcrum length of 160 mm (6.30 inch)
NOTICE: Measure preload after rotating the bearing both clockwise and counterclockwise to make it fit.
b. If the preload is too large, replace the transfer pinion bearing spacer with a new one.
c. If the preload is too small, repeatedly adjust the preload by tightening the transfer gear nut 5 to 10 degrees at a time until the standard value is obtained.
d. If the preload is insufficient, even though the tightening torque of the transfer gear nut exceeds the maximum of the standard value, loosen the transfer gear nut and apply gear oil SAE 90 (GL-5) to the transfer gear nut and the screw thread and the base of the driven pinion. And then repeat the preceding operation. If the tightening torque is smaller than the standard, replace the transfer pinion bearing spacer with a new one and adjust it.
SST 09326-20011, 09556-16030
Torque: 378 Nm (3,855 kgf-cm, 279 ft. lbs.)
49. INSTALL RING GEAR
a. Heat the ring gear in boiling water from 90 to 100°C (194 to 212°F).
b. Completely remove grease and moisture on the contact surfaces of the ring gear and the transfer ring gear mounting case.
c. Align the matchmarks on the ring gear and transfer ring gear mounting case and quickly assemble them.
d. Tighten them bolts
Torque: 78 Nm (790 kgf-cm, 57 ft. lbs.)
NOTICE:
^ Tighten the bolts in diagonal order in splitting several times.
^ After the ring gear has well cooled down, fully tighten the bolts.
^ Make the bolt heads in order to check if they are retightened or not.
50. INSTALL CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING
a. RH side: Using SST(s) and a press, install the inner race of the center differential case tapered roller bearing to the transfer ring gear mounting case.
SST 09506-35010, 09950-60010 (09951-00430)
NOTICE: When replacing the inner race, replace it together with the outer race.
b. LH side: Using SST(s) and a press, install the inner race of the center differential case tapered roller bearing to the transfer ring gear mounting case
SST 09223-00010
NOTICE: When replacing the inner race, replace it together with the outer race.