Reassembly

VF4BM TRANSFER: TRANSFER ASSEMBLY: REASSEMBLY

REASSEMBLY

1. INSTALL TRANSFER LOW PLANETARY RING GEAR






(a) Install the low planetary ring gear to the front case.
NOTE: Make sure to install the low planetary ring gear in the correct direction.





(b) Using a screwdriver, install the snap ring.
2. INSTALL HEAD PIN






(a) Install head pin.
3. INSTALL COMPRESSION SPRING
4. INSTALL TRANSFER CASE PLUG
(a) Apply sealant to the case plug threads.
Sealant:
Part NO. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
(b) Install the case plug.
Torque: 19 Nm (190 kgf-cm, 14 ft-lbf)
5. INSTALL TRANSFER OUTPUT SHAFT PLATE WASHER






(a) Install the transfer output shaft plate washer.
6. INSTALL TRANSFER DRIVE SPROCKET BEARING
7. INSTALL TRANSFER DRIVE SPROCKET SUB-ASSEMBLY
8. INSTALL NO. 1 TRANSFER OUTPUT SHAFT SPACER
9. INSTALL TRANSFER OUTPUT SHAFT REAR RADIAL BALL BEARING






(a) Using SST and a press, install a new output shaft rear radial ball bearing.
SST: 09316-60011
09316-00011
09316-00071
NOTE: Install the output shaft rear radial ball bearing so that the bearing snap ring groove face to the rear.

10. INSTALL TRANSFER OUTPUT SHAFT PLATE WASHER






(a) Install the transfer output shaft plate washer.
11. INSTALL TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING
12. INSTALL TRANSFER CLUTCH HUB
13. INSTALL CENTER DIFFERENTIAL CASE






(a) Install the center differential case.
14. INSTALL TRANSFER OUTPUT SHAFT SPACER BALL
15. INSTALL TRANSFER OUTPUT SHAFT SPACER NO. 2
16. INSTALL TRANSFER LOW PLANETARY RING GEAR HOLE SNAP RING
(a) Using a snap ring expender, install the snap ring.
17. INSPECT DRIVE SPROCKET RADIAL CLEARANCE Transfer Case Assembly

18. INSPECT DRIVE SPROCKET THRUST CLEARANCE Transfer Case Assembly

19. INSTALL TRANSFER INPUT SHAFT BEARING






(a) Using SST and a press, install a new bearing with the groove facing forward.
SST: 09223-15020
SST: 09515-30010
SST: 09950-70010
09951-07100






20. INSTALL TRANSFER LOW PLANETARY GEAR BEARING
(a) Using SST and a press, tap in a new low planetary gear bearing.
SST: 09950-60010
09951-00570
SST: 09950-70010
09951-07100
Press in depth:
7.7 to 8.3 mm (0.303 to 0.327 in.)
21. INSTALL TRANSFER LOW PLANETARY GEAR SPLINE PIECE






(a) Using a screwdriver, install the spline piece with the snap ring.
22. INSTALL TRANSFER INPUT BEARING SHAFT SNAP RING






(a) Select a snap ring that allows the minimum axial play.






(b) Using a snap ring expander, install a new snap ring.
23. INSTALL TRANSFER NO. 1 INPUT SHAFT SEAL RING






(a) Apply gear oil to the 2 oil seal rings.
(b) Engage securely to eliminate clearance as shown in the illustration.
24. INSTALL TRANSFER LOW PLANETARY GEAR BEARING
NOTE: Make sure to install the transfer low planetary gear bearing in the correct direction.





(a) Install the transfer low planetary gear bearing.
25. INSTALL NO. 1 TRANSFER THRUST BEARING RACE
26. INSTALL TRANSFER INPUT SHAFT
27. INSTALL MANUAL TRANSFER PLANETARY CARR WASHER






(a) Install the manual transfer planetary carrier washer.
28. INSTALL TRANSFER INPUT GEAR STOPPER BALL
29. INSTALL TRANSFER INPUT GEAR STOPPER
30. INSTALL TRANSFER INPUT GEAR STOPPER SHAFT SNAP RING






(a) Select an input gear stopper shaft snap ring that allows 0.05 to 0.15 mm (0.0020 to 0.0059 in.) axial play.










(b) Using a snap ring expander, install the new input gear stopper shaft snap ring.
31. INSTALL TRANSFER CASE OIL SEAL






(a) Using SST and a hammer, tap in a new oil seal until its surface is flush with the case upper surface (No. 1).
SST: 09316-60011
09316-00011
(b) Coat the lip of the oil seal with MP grease.






(c) Using SST and a hammer, tap in a new oil seal until its surface is flush with the case upper surface (No. 2).
SST: 09304-12012
Oil seal drive in depth:
-0.5 to 0.5 mm (-0.020 to 0.02 in.)
(d) Coat the lip of the oil seal with MP grease.
32. INSTALL LOW PLANETARY GEAR ASSEMBLY WITH INPUT SHAFT SUB-ASSEMBLY






(a) Install the low planetary gear assembly with input shaft sub-assembly.
HINT: If necessary, heat the front case to about 50 to 80°C (122 to 176°F).





(b) Using a snap ring expander, install the shaft snap ring.
33. INSTALL TRANSFER OIL PUMP GEAR






(a) Install transfer oil pump gear.
34. INSTALL TRANSFER OIL PUMP BODY O-RING






(a) Coat a new O-ring with gear oil and install it to the oil pump body.
35. INSTALL TRANSFER OIL PUMP BODY SUB-ASSEMBLY






(a) Install the oil pump body sub-assembly with the 3 bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 in-lbf)
36. INSTALL TRANSFER CASE MAGNET






(a) Install transfer case magnet.
37. INSTALL TRANSFER OIL SEPARATOR SUB-ASSEMBLY
(a) Install the oil separator sub-assembly with the 3 bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 in-lbf)
38. INSTALL TRANSFER CASE NO. 1 PLUG
(a) Install the case plug No. 1 (filler plug) and a new gasket.
Torque: 37 Nm (380 kgf-cm, 27 ft-lbf)
39. INSTALL TRANSFER CASE NO. 1 PLUG
(a) Install the case plug (drain plug) and a new gasket.
Torque: 37 Nm (380 kgf-cm, 27 ft-lbf)
40. INSTALL TRANSFER SHIFT ACTUATOR ASSEMBLY






(a) Install the shift actuator assembly with the 3 bolts.
Torque: 20 Nm (200 kgf-cm, 14 ft-lbf)
(b) Using a screwdriver and hammer, drive in the 2 snap rings.
41. INSTALL TRANSFER INPUT GEAR RADIAL BALL BEARING






(a) Using SST and a press, install a new input gear radial ball bearing.
SST: 09316-60011
09316-00031
42. INSTALL TRANSFER DRIVEN SPROCKET BEARING






(a) Using the press, install a new driven sprocket bearing.
43. INSTALL REAR OUTPUT SHAFT SUB-ASSEMBLY, FRONT DRIVE CHAIN AND DRIVEN SPROCKET SUB-ASSEMBLY






(a) Install the rear output shaft sub-assembly and drive sprocket to the front drive chain.






(b) Install the rear output shaft sub-assembly front drive chain and driven sprocket sub-assembly to the case rear.
- Check that the rear output shaft sub-assembly and driven sprocket sub-assembly turn lightly.
- If necessary, heat the rear case to about 50 to 80°C (122 to 176°F).





(c) Using a snap ring expander, install the snap ring.
44. INSTALL CTR DIFFERENTIAL LOCK FORK SUB-ASSEMBLY WITH FRONT DRIVE CLUTCH SLEEVE






(a) Install the CTR differential lock fork sub-assembly and front drive clutch sleeve.
(b) Install the bolt.
Torque: 24 Nm (245 kgf-cm, 18 ft-lbf)
(c) Using a screwdriver and hammer, drive in the snap ring.
NOTE: Make sure to install the fork and clutch sleeve in the correct direction.

45. INSTALL TRANSFER GEAR SHIFT FORK NO. 2 WITH TRANSFER HIGH AND LOW CLUTCH SLEEVE






(a) Install the gear shift fork No. 2 and high and low shift fork shaft and high and low clutch sleeve.
NOTE: Make sure to install the fork in the correct direction.

(b) Apply sealant to the plug No. 1 threads.
Sealant:
Part NO. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
(c) Install the spring and ball to the hole.
(d) Install the plug No. 1 to the hole.
Torque: 19 Nm (190 kgf-cm, 14 ft-lbf)
(e) Using a pin punch and hammer, install the slotted pin.
46. INSTALL TRANSFER OUTPUT SHAFT SPACER






(a) Install the transfer output shaft spacer.
47. INSTALL TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING
(a) Install the transfer output shaft front needle roller bearing.
48. INSTALL TRANSFER REAR CASE






(a) Apply FIPG to the case rear, as shown.
FIPG:
Part No. 08826-00090, THREE BOND 1281 or equivalent






(b) Install the 2 clamps and case rear with the 12 bolts.
Torque: 28 Nm (285 kgf-cm, 21 ft-lbf)
49. INSTALL COLLAR






(a) Install collar.
50. INSTALL TRANSFER OUTPUT SHAFT WASHER
(a) Install 2 output washers.
51. INSTALL TRANSFER EXTENSION HOUSING TYPE T OIL SEAL






(a) Using SST and a hammer, drive in a new oil seal until its surface is flush with the housing upper surface.
SST: 09223-46011
SST: 09631-32020
(b) Coat the lip of the oil seal with MP grease.
52. INSTALL EXTENSION HOUSING SUB-ASSEMBLY






(a) Apply FIPG to the extension housing assembly rear, as shown in the illustration.
FIPG:
Part No. 08826-00090, THREE BOND 1281 or equivalent
(b) Apply sealant to the bolt threads.
Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent






(c) Install the extension housing assembly with the 5 bolts.
Torque: 12 Nm (122 kgf-cm, 9 ft-lbf)
53. INSTALL TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL






(a) Using SST and a hammer, drive in a new oil seal (front side).
SST: 09950-60010
09951-00320
SST: 09950-70010
09951-07100
(b) Coat the lip of the oil seal with MP grease.
54. INSTALL TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL
(a) Drive in a new oil seal (rear) in the same way as the oil seal (front).
SST: 09950-60010
09951-00320
SST: 09950-70010
09951-07100
(b) Coat the lip of the oil seal with MP grease.
55. INSTALL OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY






(a) Install the companion flange sub-assembly (front side) onto the drive sprocket sub-assembly.
(b) Using SST to hold the companion flange, install a new companion flange lock nut.
SST: 09330-00021
Torque: 118 Nm (1,200 kgf-cm, 87 ft-lbf)
(c) Using a chisel and hammer, stake the companion flange lock nut.
56. INSTALL OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY
(a) Using SST, install the companion flange sub-assembly using the same procedure as for the companion flange sub-assembly (rear side).
Torque: 118 Nm (1,200 kgf-cm, 87 ft-lbf)
SST: 09330-00021
57. INSTALL BREATHER OIL DEFLECTOR
58. INSTALL TRANSFER CASE COVER SUB-ASSEMBLY






(a) Install the case cover sub-assembly with the 4 bolts.
Torque: 18 Nm (185 kgf-cm, 13 ft-lbf)
59. INSTALL TRANSFER COVER TYPE T OIL SEAL






(a) Using SST and a hammer, drive in a new oil seal until its surface is flush with the retainer upper surface.
(b) Coat the lip of the oil seal with MP grease.
SST: 09950-60010
09951-00590
SST: 09950-70010
09951-07100
60. INSTALL TRANSFER RH BEARING RETAINER SUB-ASSEMBLY






(a) Apply FIPG to the front bearing retainer sub-assembly, as shown in the illustration.
FIPG:
Part No. 08826-00090, THREE BOND 1281 or equivalent
(b) Apply sealant to the bolt threads.
Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent






(c) Install the front bearing retainer sub-assembly with the 5 bolts.
Torque: 11.5 Nm (117 kgf-cm, 8 ft-lbf)
61. INSTALL TRANSFER GEAR SHIFT HEAD NO.2






(a) Using a pin punch and hammer, install the slotted pin to the gear shift head No. 2.
62. INSTALL SWITCH






(a) Install a new gasket, the indicator switches and the case No. 1 plug.
Torque: 37 Nm (377 kgf-cm, 27 ft-lbf)
63. INSTALL HOSES






(a) Install the hose.
- Place the hose that passes between the transfer rear case and the actuator motor.
- Adjust the clamp position to prevent the excessive bent or expansion/contraction of the hose.