Repair Procedure: Installation

1. Install a NEW No.2 oil seal in the RH bearing retainer.





NOTE

The No.2 oil seal MUST be positioned so that the seal is aligned over the hole located inside the RH bearing retainer. Failure to properly align the seal so that it seals on BOTH sides of the hole (vent) will cause the transfer case to leak fluid out of the vent assembly on the RH bearing retainer.





2. Install the transfer RH bearing retainer oil seal No.2.

A. Using the SST and a press install the oil seal No.2 to the RH bearing retainer.

SST P/N 09950-60010 (09951-00360, 09951-00540, 09952-06010), 09950-70010 (09951-07150)

NOTICE

Carefully press-fit so that the oil seal is NOT tilted.

B. Apply a small amount of MP grease No.2 to the oil seal lip.

3. Install the transfer ring gear mounting case washer No.2 to the RH bearing retainer.





4. Install the center differential case tapered roller bearing.

Using the SST and a press install the outer race to the RH bearing retainer.

SST P/N 09950-60010 (09951-00620), 09950-70010 (09951-07150)

5. Install the 0-rings.

A. Apply Hypoid gear oil to the two NEW 0-rings.





B. Install the two (2) 0-rings to the RH bearing retainer.

NOTICE

Be careful NOT to twist the 0-ring and fit it into the retainer's groove properly.

6. Install the transfer RH bearing retainer sub-assembly.





A. Place the transfer case with the face where the RH bearing retainer is to be installed facing up as shown in the illustration.

B. Center-align the center differential control coupling assembly and the case.





C. Apply MP grease No.2 thinly to area A as shown in the illustration.

HINT

Apply MP grease No.2 to prevent the oil seal lip from rolling back.





D. Insert the SST into the transfer RH bearing retainer sub-assembly.

SST P/N 09387-00090

NOTICE

Insert the SST straight in order NOT to damage the oil seal.

E. With the SST and the transfer RH bearing sub-assembly in close contact install the transfer RH bearing retainer sub-assembly together with the SST into the transfer case.

NOTICE

^ Avoid interference between the case and the retainer and between the SST and the transfer ring gear mounting case.

^ Carefully check the retainer's 0-ring for damage and incorrect fitting.





HINT

^ If the engagement is tight, tap the SST with a hammer placing a brass bar on the center of the SST.

^ If the SST and retainer are NOT in close contact, the seal for the inner end of the retainer may NOT be properly aligned when the retainer goes into position. This may result in the lip of the oil seal being rolled back during installation.

^ If the SST and retainer are NOT in close contact, the center of the retainer or transfer ring gear mounting case may come out of position when the retainer is being installed. This can cause the lip of the oil seal to be rolled back.

F. Make sure that the transfer RH bearing retainer sub-assembly and transfer case contact closely.





G. Tighten the 7 bolts evenly in the order shown in the illustration.

Torque: 28 N*m (286 kgf*cm, 21 ft*lbf)





H. Remove the SST.

7. Inspect total preload.





A. Using the SST and a torque wrench measure the initial torque between the driven pinion bearing and the ring gear face.

SST P/N 09326-20011

Torque:
Used Bearing:
Driven Pinion Preload +0.15-0.30 N*m
(+1.6 - 3.1 kgf*cm, +1.3 - 2.7 in*lbf)

HINT

Use a torque wrench with a fulcrum length of 160 mm (6.30 in.).

NOTE

Measure the torque after rotating the bearing in both clockwise and counterclockwise directions to make it fit.

B. If the preload is too large replace the bearing spacer with a NEW one.

C. If the preload is too small repeatedly adjust the preload by tightening the lock nut 5 - 10 degrees at a time until the standard value is obtained.

D. If the preload is insufficient even though the tightening torque of the lock nut exceeds the maximum of the standard value loosen the lock nut and apply gear oil SAE 90 (GL-5) to the lock nut and the screw thread and base of the driven pinion. Then repeat the preceding operation. If the tightening torque is smaller than the standard replace the bearing spacer with a NEW one and adjust it.

SST P/N 09326-20011, 09556-16030

Torque: 378 N*m (3855 kgf*cm, 279 ft*lbf)

8. Install the transfer RH bearing retainer oil seal.





A. Using the SST, drive the oil seal into the RH bearing retainer to the position shown in the illustration.

SST P/N 09223-46011

NOTICE

Drive in the oil seal carefully so that it will NOT be tilted.

B. Apply MP grease to the oil seal lip.





9. Install a NEW transfer cover gasket to the case.

10. Install the transfer assembly.





A. Apply FIPG sealant 1281 to the transaxle assembly and the transfer assembly in continuous beaded form of 1.2 mm (0.05 in.) diameter as shown in the illustration.

FIPG sealant: Three Bond 1281, or equivalent

NOTICE

^ Remove any grease from the attaching surfaces.

^ Install the transfer assembly within 10 minutes after application of the sealant.

^ Sealant stuck on the gasket, case oil seal, and driving plug may cause oil leakage and seizure due to oil shortage.





B. Install the transfer assembly to the transaxle assembly with the 2 bolts and 6 nuts.

Torque: 69 N*m (700 kgf*cm, 51 ft*lbf)

NOTICE

^ Check that the gasket is installed to the transfer assembly before instaling it to the transaxle assembly.

^ Install the transfer assembly to the transaxle assembly without tilting.

^ When moving the transfer assembly, do NOT hold by the oil seals.

11. Install the automatic transmission w/transfer.





Refer to TIS applicable model and model year Repair Manual:

12. Install the engine assembly with transaxle.





Refer to TIS applicable model and model year Repair Manual:





13. Install the transfer drain plug with a NEW gasket.

Torque: 49 N*m (500 kgf*cm, 36 ft*lbf)

14. Install the transfer case No. 1 plug.

A. Add oil up to the level 0 - 5 mm (0 -0.20 in.) below the lowest end of the plug hole.

Oil quantity:

0.95 U.S. qts (0.9 L, 0.71 Imp. qts)

NOTE

Add oil slowly.

B. Install the No. 1 plug with a NEW gasket.

Torque: 49 N*m (500 kgf*cm, 36 ft*lbf)

15. Inspect and adjust front wheel alignment.





Refer to TIS applicable model and model year Repair Manual:

16. Check the ABS speed sensor signal (ABS with EBD & BA & TRAC & VSC system).





Refer to TIS applicable model and model year Repair Manual:

17. Re-initialize any affected power systems.

Refer to TIS for the applicable TSB or Repair Manual section.