TRANSFER DISASSEMBLY (VEHICLES WITH TRANSFER OIL COOLER)

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Before Service Precautions

•  To prevent foreign material from entering the transfer, perform disassembly and servicing in a clean, dust-free environment.
•  Inspect the each part while disassembling.
Warning
•   The engine stand is equipped with a self-lock mechanism. However, if the transfer is tilted, the self-lock mechanism could become inoperative. This could cause the transfer to rotate accidentally, resulting in injury. Therefore, make sure that the transfer is not tilted when it is on the engine stand. When turning the transfer, grasp the rotation handle firmly.

Transfer Component Disassembly

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1
Drain plug
2
Oil level plug
3
Oil cooler
4
Drive gear case component
5
Front carrier component


Transfer Component Disassembling Procedure

1.  Assemble the SSTs.

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2.  Install the transfer component to the SSTs.

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3.  Remove the oil cooler.

4.  Remove the drive gear case component.


Drive Gear Case Component Disassembly

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1
Oil seal (RH outer)
2
Drive gear shaft
3
Bearing cap
4
Adjustment shim
5
Spacer
6
Drive gear component
7
Bearing outer race (LH)
8
Bearing outer race (RH)
9
Bearing (RH)
10
Bearing (LH)
11
Drive gear
12
Oil seal (RH inner)
13
Oil seal (LH outer)
14
Oil seal (LH inner)
15
Baffle plate
16
Drive gear case


Drive Gear Case Component Disassembly Procedure

1.  Install the drive gear case component to the SST.

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2.  Tap the drive gear shaft using a suitable rod and hammer.

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3.  Take out the drive gear shaft from the drive gear case.

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4.  Make alignment marks on the bearing cap and drive gear case.

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5.  Remove the bearing cap.

6.  Insert a flathead screwdriver into spacer notch and remove the adjustment shim.

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Caution
•  Place a rag on the case to protect it from damage.
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7.  Remove the spacer.

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8.  Remove the drive gear component.

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9.  Using a tape-wrapped flathead screwdriver, remove the oil seal (LH outer).

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10.  Insert a flathead screwdriver in the direction of the arrow and tap the oil seal (LH inner) to remove it.

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11.  Using a tape-wrapped pliers, remove the oil seal (RH outer).

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12.  Insert a flathead screwdriver in the direction of the arrow and tap the oil seal (RH inner) to remove it.

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13.  Using the SST, remove the bearing outer race (LH).

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(1)  Install the SSTs (49 W032 202, 49 S019 005).
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(2)  Connect the SST (49 T032 316, 49 T032 317) to the SSTs (49 W032 202, 49 S019 005).
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14.  Remove the baffle plate.

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15.  Using the SST, remove the bearing (RH).

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16.  Using a flathead screwdriver, deform the bearing roller guide (LH) and remove it.

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17.  Using the SST, remove the bearing inner race (LH).

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Front Carrier Component Disassembly

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1
Oil pipe
2
Oil strainer
3
Side cover
4
Ring gear lockbolt
5
Oil pump
6
Oil pump shaft
7
Bearing cap
8
Tubular pin
9
Ring gear component
10
Adjustment shim
11
Spacer
12
Bearing outer race (side)
13
Bearing (side)
14
Ring gear
15
Ring gear shaft
16
Locknut
17
Washer
18
Companion flange
19
Oil seal
20
Drive pinion gear
21
Bearing (rear)
22
Distance piece
23
Bearing (front)
24
Spacer
25
Bearing outer race (front)
26
Bearing outer race (rear)


Front Carrier Component Disassembling Procedure

1.  Install the front carrier component to the SST.

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2.  Remove the oil strainer.

3.  Remove the oil pipe.

4.  Remove the side cover.

5.  Remove the oil pump by turning it using pliers as shown in the figure.

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•  If the oil pump shaft remains in the gear shaft side, remove the oil pump shaft.

6.  Make alignment marks on the bearing caps and front carrier.

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7.  Remove the bearing caps and tubular pins.

Note
•  If the bearing caps cannot be removed, lightly tap the bearing caps using a plastic hammer to remove them. If the bearing caps still cannot be removed, remove the bearing caps and ring gear component as a single unit in Step 11.

8.  Using a suitable wrench, secure the ring gear shaft, and remove the ring gear lockbolt.

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9.  Using the SST, secure the companion flange, and remove the locknut and washer.

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10.  Using the SST, remove the companion flange.

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11.  Using the SSTs, remove the ring gear component.

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12.  Remove the adjustment shims and spacer.

13.  Install an appropriate nut to the drive pinion to prevent the thread from being damaged.

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14.  Lightly tap the drive pinion using a copper hammer and remove the drive pinion gear.

15.  Using a flathead screwdriver, remove the oil seal.

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16.  Remove the bearing (rear) and distance piece.

17.  Using the SST, remove the bearing (front).

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18.  Remove the spacer.

19.  Attach the brass stick to the notch, tap the race end lightly and evenly, then remove the bearing outer races.

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20.  Using the SSTs, remove the bearing (side) (opposite ring gear side).

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21.  Using a SST, remove the bearing (side) (ring gear side) together with ring gear.

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Substitution SST
•  49 T032 302
Outer diameter: 25—30 mm {0.99—1.18 in}
Plate thickness: 1 mm {0.04 in} or more