Part 2

TRANSFER ASSEMBLY (4WD)
OVERHAUL
33. REMOVE DRIVEN PINION





a. Using SST and a hammer, unstake the staked part of the gear nut.
SST 09930-00010





b. Using SST, remove the gear nut.
SST 09326-20011, 09556-16030





c. Using a press, remove the driven pinion, bearing inner rear race and bearing spacer.

NOTICE:
^ Put a shop rug to prevent the driven pinion from dropping.
^ Place something like wood blocks under the case to keep it level.





34. REMOVE TRANSFER DRIVEN PINION FRONT BEARING
a. Using SST and a press, remove the inner race from the driven pinion.
SST 09950-00020





35. REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING
a. Using a brass bar and a hammer, lightly strike the outer race at 2 points to remove it from the case.
36. REMOVE RING GEAR MOUNTING CASE PLATE WASHER





37. REMOVE TRANSFER DRIVEN PINION FRONT BEARING
a. Using a brass bar and a hammer, lightly strike the outer race at 2 points to remove it from the case.
38. REMOVE TRANSFER OUTPUT WASHER





39. REMOVE TRANSFER DRIVEN PINION REAR BEARING
a. Using a brass bar and a hammer, lightly strike the outer race at 2 points to remove it from the case.





40. INSTALL TRANSFER DRIVEN PINION REAR BEARING
a. Using SST and a press, install the outer race to the case.
SST 09950-60010 (09951-00620), 09950-70010 (09951-07150)

NOTICE: Place something like wood blocks under the case to keep it level.

41. INSTALL TRANSFER OUTPUT WASHER
a. Install the washer to the case.

HINT: Reuse the washer used before disassembly.





42. INSTALL TRANSFER DRIVEN PINION FRONT BEARING
a. Install the outer race to the case with SST, a bolt and a nut.
SST 09950-60010 (09951-00750, 09951-00770, 09951-00810), 09316-60011 (09316-00061)
43. INSTALL RING GEAR MOUNTING CASE PLATE WASHER
a. Install the washer to the case.

HINT: Reuse the washer used before disassembly.





44. INSTALL CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING
a. Using SST and a press, install the outer race to the case.
SST 09950-70010 (09951-07200), 09316-60011 (09316-00021)





45. INSTALL TRANSFER DRIVEN PINION FRONT BEARING
a. Using SST and a press, install the inner race to the driven pinion.
SST 09316-60011 (09316-00041)
46. INSTALL DRIVEN PINION





a. Install the driven pinion to the case.





b. Install a new bearing spacer and a new bearing rear to the driven pinion.





c. Using SST, tighten a new gear nut with a standard torque.
SST 09326-20011, 09556-16030
Torque: 277 - 378 Nm (2,820 - 3,853 kgf-cm, 204 - 279 ft. lbs.)

NOTICE: Do not stake the gear nut.

HINT: Use a torque wrench with a fulcrum length of 750 mm (29.53 inch)





47. INSPECT AND ADJUST DRIVEN PINION PRELOAD
a. Using SST and a torque wrench, measure the initial torque of the driven pinion.
SST 09326-20011
Preload (at starting):
New bearing: 1.1 - 1.6 Nm (11 - 16 kgf-cm, 9.7 - 14.2 inch lbs.)
Used bearing: 0.9 - 1.4 Nm (9 - 14 kgf-cm, 8.0 - 12.4 inch lbs.)

HINT: Use a torque wrench with a fulcrum length of 160 mm (6.30 inch)

NOTICE: Measure it after rotating the bearing in both clockwise and counter clockwise directions to make it fit.

b. If the preload is too large, replace the bearing spacer with new one.
c. If the preload is too small, repeatedly adjust the preload by tightening the lock nut 5 - 10 degrees at a time until the standard value is obtained.
d. If the preload is insufficient even though the tightening torque of the lock nut exceeds the maximum of the standard value, loosen the lock nut and apply gear oil SAE 90 (GL-5) to the lock nut and the screw thread and the base of the driven pinion. And then repeat the preceding operation. If the tightening torque is smaller than the standard, replace the bearing spacer with new one and adjust it.
SST 09326-20011, 09556-16030
Torque: 378 Nm (3,855 kgf-cm, 279 ft. lbs.)
48. INSTALL RING GEAR





a. Heat the ring gear in boiling water to 90 - 100°C (194 - 212°F).
b. Completely remove grease and moisture on the mating surfaces of the ring gear and the ring gear mounting case.





c. Align the matchmarks on the ring gear and ring gear mounting case and quickly assemble them.
d. Tighten the12 bolts.
Torque: 78 Nm (790 kgf-cm, 57 ft. lbs.)

NOTICE:
^ Tighten the bolts in diagonal order in splitting several times.
^ After the ring gear has well cooled down, tighten the bolts.
^ Make paint marks, etc. do the procedure while checking the bolts retightened.

49. INSTALL CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING





a. RH side:
Using SST and a press, install the inner race of the center differential case tapered roller bearing to the ring gear mounting case assembly.
SST 09506-35010, 09950-60010 (09951-00430)

NOTICE: When replacing the inner race, replace the outer race, too.





b. LH side:
Using SST and a press, install the inner race of the center differential case tapered roller bearing to the ring gear mounting case assembly.
SST 09223-00010

NOTICE: When replacing the inner race, replace the outer race, too.





50. INSTALL TRANSFER RING GEAR MOUNTING CASE
a. Install the ring gear mounting case assembly to the case.

NOTICE: Damage to the spline, bearing's rotating surface and gear face may cause decrease in their strength. Care should be taken at the time of installation.

51. INSTALL TRANSFER RING GEAR MOUNTING CASE WASHER NO.2

HINT: Reuse the washer used before disassembly.





52. INSTALL CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING
a. Using SST and a press, install the outer race to the right bearing retainer.
SST 09950-60010 (09951-00620), 09950-70010 (09951-07150)
53. INSTALL TRANSFER RH BEARING RETAINER SUB-ASSEMBLY





a. Place the transfer with the face where the right bearing retainer is to be installed facing up.
b. Center-align the ring gear mounting case assembly and the case.





c. Insert the SST into the right bearing retainer.
SST 09387-00090

NOTICE: Insert SST straight in order not to damage the oil seal lip.





d. Insert the right bearing retainer together with the SST into the case.

NOTICE: Hard interference between the case and the retainer, and between the center differential control coupling assembly and SST should be carefully avoided.

HINT: If the retainer cannot be inserted, tap it in with a plastic hammer.





e. After inserting the right bearing retainer into the case, remove the SST.





f. Tighten the 7 bolts.
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)
54. INSPECT BACKLASH





a. Set the dial gauge perpendicular to the ring gear face, fix the driven pinion, and check the backlash by moving the ring gear.
Backlash: 0.10 - 0.15 mm (0.0039 - 0.0059 inch)

NOTICE: Measure it at 3 points or more on the ring gear periphery.





b. If the measured value is out of the standard, select a proper washer for the center differential case tapered roller bearing on the LH side from the table and install it to obtain the standard value.

HINT: When the backlash is larger or smaller than the standard, select a thinner or thicker washer respectively.





c. Proper washer location is shown in the illustration.
55. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVEN PINION





a. Apply red lead primer thinly and uniformly to both faces of the ring gear and rotate it several times.

NOTICE: Check the tooth contact on the ring gear at 4 places or more.





b. Observe the pattern shown by red lead primer.





c. In the case of faulty tooth contact, select a washer for the driven pinion bearing front side from the following table and reinstall it.

NOTICE: If the washer thickness is changed, the backlash will be also changed.





d. The location of the washer for tooth contact adjustment is shown in the illustration.
56. ADJUST TOTAL PRELOAD





a. Using SST and a torque wrench, measure the initial torque with the driven pinion being contact with the ring gear face.
SST 09326-20011
Torque:
New bearing:
Driven pinion preread +0.2 - 0.4 Nm (+2.3 - 3.9 kgf-cm, +1.8 - 3.5 inch lbs.)
Used bearing:
Driven pinion preload +0.15 - 0.30 Nm (+1.6 - 3.1 kgf-cm, +1.3 - 2.7 inch lbs.)

NOTICE: Before measurement, rotate the bearing in both directions several times to make it fit.

HINT: Use a torque wrench with a fulcrum length of 160 mm (6.30 inch)





b. If the value is out of the standard range, select the washer for the center differential case tapered roller bearing RH side from the following table and reinstall it.





c. The location of the washer for preload adjustment is shown in the illustration.





d. Using a chisel, stake the gear nut.
57. REMOVE TRANSFER RH BEARING RETAINER SUB-ASSEMBLY





a. Remove the 7 bolts from the right bearing retainer.





b. Using a screwdriver and a hammer, make a clearance between the right bearing retainer and the transfer case.





c. Using SST, remove the right bearing retainer from the transfer case.
SST 09520-10021





58. REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING
a. Hold the right bearing retainer in a vise.
b. Using SST, remove the outer race and washer from the right bearing retainer.
SST 09308-00010





59. INSTALL SIDE GEAR SHAFT HOLDER BEARING
a. Install the side gear shaft holder bearing to the right bearing retainer.
b. Using a snap ring pliers, install the side gear shaft holder hole snap ring.

HINT: Check that the snap ring is fit in the groove of the retainer.





60. INSTALL TRANSFER RH BEARING RETAINER OIL SEAL
a. Using SST and a press, install the oil seal to the right bearing retainer.

NOTICE: Carefully press-fit so that the oil seal will not be tilted.

b. Apply small amount of MP grease No.2 to the oil seal lip.
SST 09950-60010 (09951-00360, 09951-00540, 09952-06010), 09950-70010 (09951-07150)
61. INSTALL TRANSFER RING GEAR MOUNTING CASE WASHER NO.2
a. Install the selected ring gear mounting washer to the right bearing retainer.





62. INSTALL CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING
a. Using SST and a press, install the outer race to the right bearing retainer.
SST 09950-60010 (09951-00620), 09950-70010 (09951-07150)





63. INSTALL O-RING
a. Apply hypoid gear oil to a new O-ring.
b. Install the 2 O-rings to the right bearing retainer.

NOTICE: Be careful not to twist the O-ring and fit it into the retainer's groove properly.

64. INSTALL TRANSFER RH BEARING RETAINER SUB-ASSEMBLY





a. Place the transfer with the face where the right bearing retainer is to be installed facing up.
b. Center-align the center differential control coupling assembly and the case.





c. Insert SST into the right bearing retainer.
SST 09387-00090

NOTICE: Insert SST straight in order not to damage the oil seal.





d. Insert the right bearing retainer together with SST into the case.

NOTICE:
^ Prevent hard interference between the case and the retainer, and between the SST and the center differential control coupling assembly.
^ Carefully check for damage and incorrect fitting of the retainer's O-ring.

HINT: If the retainer cannot be inserted into the case, tap it in with a plastic hammer.





e. After inserting the right bearing retainer into the case, remove the SST.





f. Tighten the 7 bolts.
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)