Part 1

TRANSFER UNIT

Components:

DISASSEMBLY

1. REMOVE TRANSFER COVER GASKET
a. Remove the transfer gasket from the transfer assembly.

2. REMOVE TRANSFER CASE BREATHER PLUG
a. Using a screwdriver and a hammer, remove the transfer case breather plug from the No. 1 transfer case cover.

NOTICE: Be careful not to damage the contact surface of No. 1 case cover.

3. REMOVE NO. 1 TRANSFER CASE COVER
a. Remove the 8 bolts.

b. Using a brass bar and a hammer, remove the No. 1 transfer case cover from the transfer case.

NOTICE: Be careful not to damage the contact surfaces of the case and cover.

4. REMOVE BREATHER OIL DEFLECTOR
a. Remove the bolt and breather oil deflector from the No. 1 transfer case cover.

5. REMOVE TRANSFER DYNAMIC DAMPER
a. Remove the 3 bolts and the transfer dynamic damper from the transfer extension housing subassembly.
6. REMOVE TRANSFER CASE STRAIGHT PIN
a. Remove the 4 transfer case straight pins from the transfer case.
7. REMOVE TRANSFER AND TRANSAXLE SETTING STUD BOLT
a. Remove the 4 transfer and transaxle setting stud bolts.
8. FIX TRANSFER ASSEMBLY
a. Fix the transfer assembly to the overhaul attachment.

9. REMOVE TRANSFER EXTENSION HOUSING DUST DEFLECTOR
a. Using a plastic hammer, remove the transfer extension housing dust deflector from the transfer extension housing sub-assembly.

10. REMOVE TRANSFER EXTENSION HOUSING TYPE T OIL SEAL
a. Using SST(s), remove the transfer extension housing type T oil seal from the transfer extension housing.
SST 09308-00010

NOTICE: Be careful not to damage the oil-seal-fitted surface of the housing and the inside surface of the bush.

11. REMOVE TRANSFER EXTENSION HOUSING SUB-ASSEMBLY
a. Remove the 4 bolts.

b. Using a plastic hammer, remove the transfer extension housing sub- assembly from the transfer case.

12. INSPECT PRELOAD
a. Using SST(s) and a torque wrench, check the initial torque with the backlash range.
SST 09326-20011
Torque: 0.9 to 1.4 Nm (9 to 14 kgf-cm, 8.0 to 12.4 inch lbs.)

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

b. Using SST(s) and a torque wrench, check the initial torque while the driven pinion is in contact with the ring gear face.
SST 09326-20011
Torque: Preload 0.15 to 0.30 Nm (+1.6 to 3.1 kgf-cm, +1.3 to 2.7 inch lbs.)

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

13. REMOVE CTR DIFFERENTIAL LOCK SLEEVE
a. Using snap ring pliers, remove the shaft snap ring.

b. Using SST(s), remove the CTR differential lock sleeve.
SST 09308-00010

14. REMOVE O-RING
a. Using a screwdriver with the tip protected by vinyl tape, remove the O-ring from the CTR differential lock sleeve.

NOTICE: Be careful not to damage the lock sleeve's groove for the O-ring.

15. REMOVE TRANSFER CASE OIL SEAL
a. Using SST(s), remove the transfer case oil seal from the case.
SST 09308-00010

NOTICE: Be careful not to damage the oil-seal-fitted surface of the case.

16. REMOVE TRANSFER RH BEARING RETAINER OIL SEAL
a. Using SST(s), remove the transfer RH bearing retainer oil seal from the transfer RH bearing retainer sub-assembly.
SST 09308-00010

NOTICE: Be careful not to damage the oil-seal-fitted surface of the retainer.

17. REMOVE TRANSFER RH BEARING RETAINER SUB-ASSEMBLY
a. Remove the 7 bolts from the transfer RH bearing retainer sub-assembly.

b. Using a screwdriver and a hammer, create a clearance between the transfer RH bearing retainer sub-assembly and the transfer case.

NOTICE: Be careful not to damage the transfer RH bearing retainer sub-assembly and the transfer case.

c. Using SST(s), remove the transfer RH bearing retainer sub-assembly from the transfer case.
SST 09520-10021

18. REMOVE O-RING
a. Using a screwdriver with the tip protected by vinyl tape, remove the 2 O-rings from the transfer RH bearing retainer sub-assembly.

NOTICE: Be careful not to damage the retainer's grooves for the O-rings.

19. REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING
a. Fix the transfer RH bearing retainer sub-assembly in a vise.
b. Using SST(s), remove the center differential case tapered roller bearing RH outer race, transfer ring gear mounting case washer No. 2 and right bearing retainer oil seal No. 2 from the transfer RH bearing retainer sub-assembly.
SST 09308-00010

NOTICE: Be careful not to damage the oil-seal-fitted surface of the transfer RH bearing retainer sub assembly.

20. REMOVE SIDE GEAR SHAFT HOLDER BEARING
a. Using snap ring pliers, remove the side gear shaft holder hole snap ring.
b. Remove the side gear shaft holder bearing from the transfer RH bearing retainer sub-assembly.

21. REMOVE TRANSFER RING GEAR MOUNTING CASE
a. Remove the transfer ring gear mounting case from the transfer case.

22. REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING
a. Using SST(s), remove the inner race of the center differential case tapered roller bearing from the transfer ring gear mounting case.

NOTICE: Apply grease to the screw thread and tip of the SST(s) before use.

b. When the roller comes off due to deformation of the gauge, completely remove the roller and remaining inner races of the center differential case tapered roller bearing from the transfer ring gear mounting case.

NOTICE: Apply grease to the screw thread and tip of the SST(s) before use.

c. Using SST(s), remove the inner race of the center differential case tapered roller bearing from the transfer ring gear mounting case.

NOTICE: Apply grease to the screw thread and tip of the SST(s) before use.

d. When the roller comes off due to deformation of the gauge, completely remove the roller and remaining inner races of the center differential case tapered roller bearing from the transfer ring gear mounting case.

NOTICE: Apply grease to the screw thread and tip of the SST(s) before use.

23. REMOVE RING GEAR
a. Put matchmarks on the transfer ring gear mounting case and the ring gear.
b. Remove the 12 bolts.

c. Using a plastic hammer, remove the ring gear by tapping around its periphery.

NOTICE: Do not damage the teeth of the ring gear.

24. REMOVE TRANSFER GEAR NUT
a. Using SST(s) and a hammer, unstake the transfer gear nut.
SST 09930-00010

b. Using SST(s), remove the transfer gear nut.

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

NOTICE:
^ Put shop cloths around to help prevent the driven pinion from bearing dropped.
^ Place something like wood blocks under the case to keep it level.

25. REMOVE TRANSFER DRIVEN PINION FRONT BEARING
a. Using SST(s) and a press, remove the transfer driven pinion front bearing inner race from the driven pinion.
SST 09950-00020

26. REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING
a. Using a brass bar and a hammer, lightly strike the center differential case tapered roller bearing LH outer race at 2 positions to remove it from the transfer case.
27. REMOVE TRANSFER OUTPUT WASHER
a. Remove the ring gear mounting case plate washer from the transfer case.

28. REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING
a. Using brass bar and a hammer, lightly strike the transfer driven pinion front bearing outer race at 2 points to remove it from the transfer case.
29. REMOVE RING GEAR MOUNTING CASE PLATE WASHER
a. Remove the transfer output washer from the transfer case.

30. REMOVE TRANSFER DRIVEN PINION REAR BEARING
a. Using a brass bar and a hammer, lightly strike the transfer driven pinion rear bearing outer race at 2 points to remove it from the transfer case.

INSPECTION

1. INSPECT PRELOAD
a. Using SST(s) and a torque wrench, check the initial torque within the backlash range.
SST 09326-20011
Torque: 0.9 to 1.4 Nm (9 to 14 kgf-cm, 8.0 to 12.4 inch lbs.)

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

b. Using SST(s) and a torque wrench, check the initial torque while the driven pinion is in contact with the ring gear face.
SST 09326-20011
Torque: Preload +0.15 to 0.30 Nm (+1.6 to 3.1 kgf-cm, +1.3 to 2.7 inch lbs.)

HINT: Use a torque wrench with a fulcrum length of 160 mm (6.3 0 inch).

2. INSPECT DIFFERENTIAL RING GEAR BACKLASH
a. Set the dial gauge perpendicular to the tooth face of the ring gear, fix the driven pinion and inspect the backlash while moving the gear.
Backlash: 0.10 to 0.15 mm (0.0039 to 0.0059 inch)

NOTICE: Inspect it at 3 points or more on the gear's periphery.

3. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION
a. Apply red lead primer thinly and uniformly to both faces of the ring gear and rotate several times.

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

4. INSPECT RUNOUT OF TRANSFER RING GEAR MOUNTING CASE
a. Using a dial gauge check the transfer ring gear mounting case runout.
Maximum runout: 0.03 mm (0.0012 inch)

REASSEMBLY

1. INSTALL TRANSFER DRIVEN PINION REAR BEARING
a. Using SST(s) and a press, install the transfer driven pinion rear bearing outer race to the transfer case.
SST 09950-60010 (09951-00620), 09950-70010 (09951-07150)

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

2. INSTALL TRANSFER OUTPUT WASHER
a. Install the transfer output washer to the transfer case.

HINT: Reuse the washer.

3. INSTALL TRANSFER DRIVEN PINION FRONT BEARING
a. Install the transfer driven pinion front bearing outer race to the transfer case with SST(s), bolt and nut.
SST 09950-60020 (09951-00750, 09951-00770, 09951-00810), 09316-60011 (09316-00061)
4. INSTALL RING GEAR MOUNTING CASE PLATE WASHER
a. Install the ring gear mounting case plate washer to the transfer case.

HINT: Reuse the washer.

5. INSTALL CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING
a. Using SST(s) and a press, install the center differential case tapered roller bearing LH outer race to the transfer case.
SST 09950-70010 (09951-07200), 09316-60011 (09316-00021)

6. INSTALL TRANSFER DRIVEN PINION FRONT BEARING
a. Using SST(s) and a press, install the transfer driven pinion front bearing inner race to the driven pinion.

7. INSTALL DRIVEN PINION
a. Install the driven pinion to the transfer case.

b. Install a new transfer pinion bearing spacer and anew transfer driven pinion rear bearing inner race to the driven pinion.

c. Using SST(s), tighten a new transfer gear nut (at a standard torque.)
SST 09326-20011, 09556-16030
Torque: 277 to 378 Nm (2,820 to 3,855 kgf-cm, 204 to 279 ft. lbs.)

NOTICE: Do not stake the transfer gear nut.

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

8. INSPECT AND ADJUST DRIVEN PINION PRELOAD
a. Using SST(s) and a torque wrench, measure thee initial torque of the driven pinion.
SST 09326-20011, 09556-16030
Torque:
New bearing 1.1 to 1.6 Nm (10 to 16 kgf-cm, 9.7 to 14.2 inch lbs.)
Used bearing 0.9 to 1.4 Nm (9 to 14 kgf-cm, 8.0 to 12.4 inch lbs.)

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

NOTICE: Measure preload after rotating the bearing both clockwise and counterclockwise to make it fit.

b. If the preload is too large, replace the transfer pinion bearing spacer with a new one.
c. If the preload is too small, repeatedly adjust the preload by tightening the transfer gear nut 5 to 10 degrees at a time until the standard value is obtained.
d. If the preload is insufficient, even though the tightening torque of the transfer gear nut exceeds the maximum of the standard value., loosen the transfer gear nut and apply gear oil SAE 90 (GL-5) to the transfer gear nut and the screw thread and the base of driven pinion. And then repeat the preceding operation . If the tightening torque is bearing spacer with anew one and adjust it.
Torque: 378 Nm (3.855 kgf-cm, 279 ft. lbs.)

9. INSTALL RING GEAR
a. Heat the ring gear in boiling water from 90 to 100°C (194 to 212°F).
b. Completely remove grease and moisture on the contact surfaces of the ring gear and the transfer ring gear mounting case.

c. Align the matchmarks on the ring gear and transfer ring gear mounting case and quickly assemble them.
d. Tighten the 12 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, fully tighten the bolts.
^ Make the bolt heads in order to check if they are retightened or not.

10. INSTALL CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING
a. Using SST(s) and a press, install the inner race of the center differential case tapered roller bearing to the transfer ring gear mounting case.
SST 09506-35010, 09950-60010 (09951-00430), 09223-00010

NOTICE: When replacing the inner race, replace it together with the outer race.

11. INSTALL TRANSFER RING GEAR MOUNTING CASE
a. Install the transfer ring gear mounting case to the transfer case.

NOTICE: Damage to the spline, the bearing's rotating surface and gear face may cause a decrease in their strength. Care should be taken when installing them.

12. INSTALL NO. 2 TRANSFER RING GEAR MOUNTING CASE WASHER
a. Install the No. 2 transfer ring gear mounting case washer to the transfer RH bearing retainer sub assembly.

HINT: Reuse the washer.

13. INSTALL CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING
a. Using SST(s) and a press, install the center differential case tapered roller bearing RH outer race to the transfer RH bearing retainer subassembly.
SST 09950-60010 (09951-00620), 09950-70010 (09951-07150)

14. INSTALL TRANSFER RH BEARING RETAINER SUB-ASSEMBLY
a. Place the transfer the face where the transfer RH bearing retainer sub-assembly is to be installed facing up.
b. Center-align the transfer ring gear mounting case and the transfer case.

c. Install the SST(s) into the transfer RH bearing retainer sub-assembly

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

d. Insert the transfer RH bearing retainer sub assembly together with the SST(s) into the transfer case.

NOTICE: Interference between the case and retainer, and between the transfer ring gear mounting case and SST(s) should be carefully avoided.

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

e. After inserting the transfer RH bearing retainer subassembly into the transfer case, remove the SST(s).

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

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

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

b. If the measured value is out of 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.

c. Ring gear mounting case plate washer location is shown in the illustration.