TRANSFER DISASSEMBLY

d6e031627500102


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

e6u316zmc100

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.

e6u316zmc014

2.  Install the transfer component to the SSTs.

e6u316zmc015

3.  Remove the oil cooler.

4.  Remove the drive gear case component.


Drive Gear Case Component Disassembly

e6u316zmc102

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)
14
Baffle plate
15
Drive gear case


Drive Gear Case Component Disassembly Procedure

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

e6u316zmc001

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

e6u316zmc065

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

e6u316zmc004

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

e6u316zmc005

5.  Remove the bearing cap.

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

e6u316zmc006

Caution
•  Place a rag on the case to protect it from damage.
e6u316zmc007

7.  Remove the spacer.

e6u316zmc008

8.  Remove the drive gear component.

e6u316zmc009

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

e6u316zmc201

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

e6u316zmc202

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

e6u316zmc203

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

e6u316zmc010

(1)  Install the SSTs (49 W032 202, 49 S019 005).
e6u316zmc109
(2)  Connect the SST (49 T032 316, 49 T032 317) to the SSTs (49 W032 202, 49 S019 005).
e6u316zmc018

13.  Remove the baffle plate.

e6u316zmc107

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

e6u316zmc021

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

e6u316zmc019

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

e6u316zmc020


Front Carrier Component Disassembly

e6u316zmc103

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


Front Carrier Component Disassembling Procedure

1.  Install the front carrier component to the SST.

e6u316zmc022

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.

e6u316zmc024

•  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.

e6u316zmc112

7.  Remove the bearing caps.

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

e6u316zmc023

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

buj0517a349

10.  Using the SST, remove the companion flange.

buj0517a350

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

e6u316zmc026

12.  Remove the adjustment shims and spacer.

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

buj0517a353

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.

e6u316zmc027

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

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

e6u316zmc028

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.

e6u316zmc029
e6u316zmc030

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

e6u316zmc114

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

e6u316zmc031