Transfer Assembly
TRANSFER ASSEMBLY1. INSTALL CASE SIDE
a. Install the plate washer.
HINT: First install a washer of the same thickness as before.
b. Using SST and a press, press in the outer race.
SST 09316-60011 (09316-00011, 09316-00061)
2. INSTALL RIGHT CASE SIDE
a. Using SST and a press, press in outer race as shown.
SST 09316-60011 (09316-00011, 09316-00061)
b. Install the bearing adjusting nut and oil reservoir, until it touches the outer race.
3. ADJUST RING GEAR BACKLASH
a. Install the 2 shims to the driven pinion bearing cage assembly.
HINT: First install shims of the same thickness as before.
b. Install the driven pinion bearing cage.
Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)
HINT: Do not install the O-ring.
c. Install the ring gear mounting case and center differential case.
d. Using a dial indicator, measure the ring gear backlash.
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)
Plate washer thickness
e. Referring to the table, select the plate washer which will ensure that the backlash is within specification. Try to select a washer of the same size as the removed washer.
4. ADJUST TOTAL PRELOAD
a. Install the transfer right case.
b. Install and torque the 10 bolts.
NOTICE: Do not apply FIPG.
HINT: Each bolt length is indicated below.
Bolt length
Bolt A: 51 mm (2.01 inch)
Bolt 8: 77 mm (3.03 inch)
Torque: 44 Nm (450 kgf-cm, 33 ft. lbs.)
c. Using SST and a spring tension gauge, measure the total preload.
SST 09326-20011
Preload (at starting):
New bearing
Driven pinion preload plus 12.7 - 13.7 N
(1.3 - 1.4 kgf, 2.9 - 3.1 lbs.)
Reused bearing
Driven pinion preload plus 4.9 - 8.8 N
(0.5 - 0.9 kgf, 1.1 - 2.0 lbs.)
HINT: Turn the drive pinion counterclockwise and clockwise several times.
d. Adjust the total preload by tightening the adjusting nut with SST.
SST 09318-12010
HINT: Measure the preload while tightening the bearing adjusting nut a little at a time.
5. CHECK RING GEAR BACKLASH
a. Using a dial indicator, measure the ring gear backlash.
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)
b. When the backlash is outside the standard value, select a different plate washer to the one selected in step 3. Again adjust the backlash and total preload.
6. CHECK TOOTH CONTACT
a. Coat 3 or 4 teeth at 4 different positions on the ring gear with red lead.
b. Rotate the ring gear, inspect the teeth contact.
c. If the teeth are not connecting properly, use the following table to select a proper shim for connection.
Shim thickness
7. REMOVE TRANSFER RIGHT CASE
Remove the 10 bolts and transfer right case.
8. REMOVE RING GEAR MOUNTING CASE AND CENTER DIFFERENTIAL CASE
9. REMOVE DRIVEN PINION BEARING CAGE ASSEMBLY
Remove the 6 bolts and driven pinion bearing cage assembly.
10. REMOVE DIFFERENTIAL LEFT SIDE BEARING OUTER RACE AND PLATE WASHER Using SST, remove the outer race and plate washer.
SST 09308-00010
11. INSTALL OIL SEAL
a. Using SST and a hammer, drive in a new oil seal.
SST 09316-60011 (09316-00011, 09316-00031)
Oil seal depth: 3.0 mm (0.120 inch)
b. Coat the lip of oil seal with MP grease.
12. INSTALL LEFT CASE BEARING OUTER RACE
a. Install the plate washer (previously selected).
b. Using SST and a press, press in the outer race.
SST 09316-60011 (09316-00011, 09316-00061)
13. INSTALL DRIVEN PINION BEARING CAGE ASSEMBLY
a. Coat the O-ring with gear oil, and install it to the bearing cage assembly.
b. Install the bearing cage with adjust shim (previously selected) to the transfer left case.
c. Install and torque the 6 bolts.
Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)
14. INSTALL RING GEAR MOUNTING CASE AND CENTER DIFFERENTIAL CASE
15. INSTALL TRANSFER RIGHT CASE
a. Install a new apply gasket to the left case.
b. Coat the O-ring with gear oil.
c. Install the O-ring to the oil pump strainer.
d. Install the oil pump strainer to the transfer right case.
e. Install and torque the bolt.
Torque: 6.4 Nm (55 kgf-cm, 48 inch lbs.)
f. Install the oil pump driven gear.
g. Remove any FIPG material and be careful not to drop oil on the contacting surfaces of the transfer left case or right case.
h. Apply FIPG to the left case.
FIPG: Part No. 08826-00090 THREE BOND 1281 or equivalent
i. Install the right case to the left case.
j. Install and torque the 10 bolts.
HINT: Each bolt length is indicated below.
Bolt length
Bolt A: 51 mm (2.01 inch)
Bolt B: 77 mm (3.03 inch)
Torque: 44 Nm (450 kgf-cm, 33 ft. lbs.)
16. CHECK TOTAL PRELOAD
17. INSTALL ADJUSTING NUT LOCK PLATE
a. Install the lock plate so that the projection from the lock plate fits properly into the groove of the adjusting nut.
HINT: When the lock plate cannot be installed, tighten the adjusting nut the smallest amount possible.
b. Coat a new O-ring with gear oil and install it to the lock bolt.
c. Install and torque the lock bolt.
Torque: 7.0 Nm (73 kgf-cm, 63 inch lbs.)
18. INSTALL TRANSFER INSPECTION HOLE COVER
a. Apply FIPG to the left case.
FIPG: Parts No. 08826-00090 THREE BOND 1281 or equivalent
b. Install the hole cover to the transfer left case.
c. Install and torque the 3 bolts.
Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)
19. INSTALL TRANSFER RIGHT CASE RETAINER
a. Coat anew O-ring with gear oil, and install it and new apply gasket.
b. Install the right case retainer to the transfer right case.
c. Install and torque the 5 bolts.
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)
20. INSTALL EXTENSION HOUSING
a. Using SST and a hammer, drive in a new oil seal.
SST 09325-20010
b. Coat the lip of the oil seal with MP grease.
c. Coat a new O-ring with gear oil and install it to the extension housing.
d. Install the extension housing to the driven pinion bearing cage.
e. Install and torque the 4 bolts.
Torque: 25 Nm (260 kgf-cm, 19 ft. lbs.)
f. Using a plastic hammer, install the dust deflector.
21. INSTALL REAR WHEEL SPEED SENSOR
a. Install a new O-ring to the speed sensor.
b. Install the speed sensor to the transfer left case.
c. Install and torque a bolt.
Torque: 5.4 Nm (56 kgf-cm, 48 inch lbs.)