TRANSFER DISASSEMBLY

BUE051727500A04

Before Service Precautions

• To prevent the foreign material from entering the transfer, perform disassembly and servicing in a clean, dust-free environment.

• Inspect the each part while disassembling.

• Disassemble with bare hand or using vinyl gloves. To prevent foreign material from entering the transfer, do not use cotton work gloves or rag.

• When disassembling areas of the transfer that are made of light alloy, tap lightly with a plastic hammer. Do not use a flathead screwdriver.

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.

Disassembly

.

1
Side cover
2
Rear cover
3
Locknut (idle gear)
4
Locknut (companion flange)
5
Washer
6
Companion flange
7
Oil seal
8
Idle gear
9
Spacer
10
Bearing cap
11
Spacer
12
Adjustment shim
13
Ring gear component
14
Bearing outer race (side)
15
Drive pinion gear
16
Bearing inner race (rear)
17
Collapsible spacer
18
Bearing inner race (front)
19
Spacer
20
Clip
21
Bearing
22
Oil seal
23
Spacer
24
Bearing outer race (rear)
25
Bearing outer race (front)
26
Bearing inner race (side)
27
Ring gear
28
Ring gear shaft
29
Transfer carrier

Disassembling Procedure

1. Remove the rear cover and drain the transfer oil.

2. Assemble the SST.

3. Install the transfer to the SST.

4. Remove the side cover.

5. Remove the O-ring from the side cover.

6. Using the SST, secure the companion flange, and remove the idle gear locknut.

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

8. Using the SST, remove the companion flange.

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

10. Using a copper hammer and pin punch, tap the idle gear locknut lightly to remove the idle gear.

11. Remove the spacer (locknut side).

12. Make alignment marks on the bearing cap and carrier.

13. Remove the bearing cap.

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

15. Remove the spacer (idle gear side).

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

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

18. Remove the bearing inner race (rear) and distance piece.

19. Using the SST, remove the bearing inner race (front).

20. Remove the spacer.

21. Detach the clip.

22. Using the SST, remove the bearing.

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

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

25. Using the SSTs, remove the bearing inner race (side) (locknut side).

26. Using the SSTs, remove the bearing inner race (side), then remove the ring gear.