Transfer Case Assembly

Fig. 7, Exploded View Of Transfer Case Assembly:

Fig. 12, Needle Bearing Replacement:

1. Using tool No. J-37757, or equivalent, install center case needle bearing, Fig. 12.
2. Using driver tool No. J-37751, or equivalent, install center case oil seal until seal is flush with case.
3. Install oil gutter, then apply suitable Loctite to the gutter attaching bolt. Tighten bolt to specification.
4. Using tool No. J-37757, or equivalent, install rear case needle bearing, Fig. 12.
5. Using driver tool No. J-37751, or equivalent, install rear case oil seal until seal is flush with case. Coat seal lip with suitable grease.
6. Using installer tool No. J-35664, or equivalent, and a suitable press, install output front shaft bearings.
7. Install output front shaft into center case.

Fig. 13, Output Rear Shaft Bearing No. 1 Replacement:

8. Using driver tool Nos. J-35664 and J-37753, or equivalents, install output rear shaft bearing, Fig. 13.
9. Install needle bearing, low gear and reduction clutch hub on output rear shaft, then the snap ring, Fig. 7.

Fig. 14, Output Rear Shaft Replacement:

10. Using tool No. J-36183, or equivalent, install output rear shaft assembly into center case, Fig. 14.
11. Install fork to shift shaft.
12. Install front drive clutch hub and sleeve. Punch mark on hub should face rear side of vehicle.
13. Install front drive fork shaft assembly, sleeve and hub in center case, then the locating ball, spring and bolt in case.

Fig. 15, Drive Chain And Rear Sprocket Replacement:

14. Install output rear shaft sprocket, then the chain, Fig. 15.

Fig. 16, Output Rear Shaft Needle Bearing And Bushing Replacement:

15. Install needle bearing and bushing on sprocket, then the steel ball, Fig. 16.

Fig. 17, Output Rear Shaft Bearing No. 2 Replacement:

16. Using tool No. J-37757-2, or equivalent, install output rear shaft bearing support lower end of shaft, Fig. 17.
17. Install bearing circlip, then the speedometer drive gear and circlip.

Fig. 18, Interlock Steel Ball Replacement:

18. Install interlock steel ball, Fig. 18.
19. Install reduction clutch hub and sleeve with reduction shift shaft assembly into center case. When installing reduction shift shaft, front drive shift shaft must be in 4WD position.

Fig. 19, Reduction Shifter Assembly Replacement:

20. Install locating ball, spring and bolt, Fig. 19.
21. Apply suitable sealant to rubber plug and install, Fig. 19.
22. Install steel ball, thrust washer, needle bearing and spacer to countershaft, then install countershaft into case.
23. Install countergear, steel ball and thrust washer, then the low gear needle bearing.
24. Using driver tool No. J-6133-01, or equivalent, install circlip on input gear, then press bearing on input gear.
25. Install bearing retainer circlip.
26. Install front case oil seal.
27. Install input gear into front case, then the circlip.
28. Lubricate rotating parts, then clean mating surfaces of both cases.
29. Apply suitable sealant to front case mating surface, then assemble front and center cases. Ensure input gear meshes with countergear.
30. Install front case bolts. Tighten bolts to specification.
31. Install countershaft plate bolt, apply suitable Loctite and tighten bolt to specification
32. Check for proper operation of front driveshaft and that input gear and output shaft rotate smoothly.

Fig. 20, Rear Case Dimension "A" Measurement:

33. Measure rear case dimension A as shown, Fig. 20.

Fig. 21, Rear Case Dimension "B" Measurement:

34. Measure bearing height B as shown, Fig. 21.
35. Subtract measurement B from A and select suitable shim.
36. Clean center and rear case mating surfaces, then apply suitable sealant and assemble cases.
37. Install case attaching bolts and tighten to specification.
38. Install universal joint flange, then check rotation of rear shaft to ensure it is smooth.

Fig. 22, Shaft Yoke Replacement:

39. Shift reduction shift shaft to the left, then install yoke on shaft and secure with retaining pin, Fig. 22.
40. Tighten locating spring bolts to specification.
41. Install steel ball and 4WD switch. Tighten switch to specification.
42. Install gearshift lever case to rear case using suitable sealant. Tighten attaching bolts to specification.
43. Install gear shift lever temporarily and check operation of transmission.