Transfer Clutch

Transfer Clutch

REMOVAL
1) Remove the transmission assembly from vehicle body.
2) Remove the extension case, and then remove the transfer clutch.

INSTALLATION
1) Select the thrust needle bearing.
2) Install the transfer clutch assembly to the extension case.





3) Tighten bolts to secure the extension case.





4) Install the transmission assembly to the vehicle.

DISASSEMBLY
1) Remove the sealing from the rear drive shaft.





2) Remove the ball bearing using the ST and the press.
ST 498077600 REMOVER





3) Using a flat tip screwdriver, etc. remove the snap ring, and take out the retaining plate, drive plate and driven plate.





4) Using the ST1, ST2 and ST3, remove the snap ring, then take out the return spring and transfer clutch piston seal.
ST1 399893600 PLIERS
ST2 398673600 COMPRESSOR
ST3 398623600 SEAT





5) Apply compressed air to the rear drive shaft, to remove the transfer clutch piston.





ASSEMBLY
1) Attach the transfer clutch piston to the rear drive shaft.





2) Install the return spring to transfer clutch piston.





3) Apply ATF to the lip of transfer clutch piston seal, then install.





4) Attach the ST to the rear drive shaft.
ST 499257300 SNAP RING OUTER GUIDE





5) Install the snap ring to the ST.
ST 499257300 SNAP RING OUTER GUIDE





6) Install the snap ring to the rear drive shaft using ST1 and ST2.
ST1 499257300 SNAP RING OUTER GUIDE
ST2 499247400 INSTALLER





7) Install the driven plate, drive plate, retaining plate and snap ring.





8) Apply compressed air to see if the assembled parts move smoothly.





9) Check the clearance between the snap ring and retaining plate.
10) Press-fit the ball bearing using the ST.

NOTE:
Use a new ball bearing.

ST 899580100 INSTALLER





11) Apply Vaseline to the seal ring and attach it to the seal ring groove of the rear drive shaft.

NOTE:
^ Use a new seal ring.
^ While installing the seal ring, not to stretch the seal ring excessively.





12) Install the transfer clutch assembly while taking care not to damage the seal ring.





INSPECTION
^ Inspect the drive plate facing for wear and damage.
^ Make sure the snap ring is not worn and the return spring has no permanent distortion, damage, or deformation.
^ Inspect the D-ring for damage.
^ Inspect the extension end play, and adjust it to within the standard value.
1) Check the clearance between the snap ring and retaining plate.
2) Before measuring clearance, place same thickness shims on both sides to prevent the retaining plate from tilting.
3) If the clearance exceeds the service limits, replace the plate set (drive plate and driven plate), and select and adjust a retaining plate to be within the initial standard value.








4) Check for tight corner braking phenomenon when the vehicle is moved forward with the steering fully turned. If tight corner braking occurs, perform the following procedures.
1) With the steering wheel held at fully turned position, drive the vehicle in "D" range and with vehicle speed at approx. 5 km/h (3 MPH) in both clockwise and counterclockwise directions for approx. ten times each, while repeating acceleration and braking intermittently.
2) If the tight corner braking phenomenon still persists, drive the vehicle again in a circle for several laps.

ADJUSTMENT
1) Measure the distance "A" from the end of ST to the rear drive shaft using the ST.
ST 398643600 GAUGE





2) Measure distance "B" from the transmission case mating surface to the end of ST using ST1 and ST2.
ST1 398643600 GAUGE
ST2 499577000 GAUGE





3) Calculation formula:
T = A - B + 35.4 mm
[T = A - B + 1.3937 in]
T: Thrust needle bearing thickness
A: Distance from the end of the ST to end of rear drive shaft
B: Distance from the mating surface of the transmission case to the end of the ST