Transfer Cover Assembly

Transfer Cover Assembly





Disassembled View
Disassembly





1. Using snap ring pliers, remove the snap ring.





2. Strike the speed gear and tone wheel with a rod or other appropriate tool from the outside of the transfer cover assembly, and remove the ball bearing and speed gear and tone wheel.

Notice: Pay attention not to damage the speed gear teeth.





3. Remove the stopper plate on the back with a precision screwdriver or other appropriate tool starting from the small lock of the plate.

Notice: Pay attention not to damage the stopper plate during the work.





4. Using a terminal pull-out tool or an equivalent tool, push down the lock to unlatch the terminal for the coil assembly, and pull the terminal out.

Notice: Pay attention not to damage other terminals.





5. Remove the fixing nuts of the coil assembly from the outside of the transfer cover assembly. Remove the coil assembly from the transfer cover.





6. Using the bearing remover J-42805 and slide hammer J-2619-01, remove the ball bearing for the front output shaft.





7. Remove the bolts and front and rear speed sensors.

Notice: Pay attention not to damage the speed sensors during the work.

Reassembly
1. Remove the oil seal from the transfer cover assembly.
2. Apply oil to the circumference of the new oil seal and fill the lip with grease (Besco L2 or equivalent).





3. Using the oil seal installer J-42804, attach the oil seal to the transfer cover assembly.





Rear Output Shaft Oil Seal
Distance between the transfer case end and oil seal.
Dimension: 9.85 - 10.35 mm (0.39 - 0.41 inch)

Notice: When installing the oil seal to the specified dimension, be careful not to damage it.

4. Apply grease to the seal ring of each front and rear speed sensor, and mount the sensors carefully.
5. Tighten the bolt with the specified torque.
Torque: 5 Nm (43 inch lbs.)

Notice: Pay attention not to mount the front (or rear) sensor to the rear (or front) sensor position.





6. Mount the ball bearing (1) for the front output shaft flat as shown in the figure.
7. Mount the coil assembly and tighten the set nuts with the specified torque.
Torque: 10 Nm (87 inch lbs.)
8. Connect the terminal in the central connector.

Notice: Be careful not to damage other terminals.

9. Set speed gear and tone wheel.





10. Mount the ball bearing (2) flat as shown in the figure.
11. Using snap ring pliers, install the snap ring to the transfer cover assembly.

Notice: Securely mount the snap ring to the groove of the transfer cover assembly.