Part 1
TRANSFER UNIT
Components
Removal
1. RAISE VEHICLE
NOTICE: Make sure that the vehicle is securely supported.
2. REMOVE TRANSFER CASE PROTECTOR
Remove the 3 bolts and transfer case protector.
Torque: 28 Nm (290 kgf-cm, 21 ft. lbs.)
3. DRAIN TRANSFER OIL
Oil grade: API GL-4 or GL-5
Viscosity: SAE 75 W-90
Capacity : 1.3 liters (1.4 US qts, 1.1 Imp. qts)
Torque: 37 Nm (380 kgf-cm, 27 ft. lbs.)
4. REMOVE FRONT AND REAR PROPELLER SHAFTS
5. DISCONNECT TRANSFER SHIFT LEVER ROD ASSEMBLY
Remove the clip, plate washer, wave washer and bushing, and disconnect the transfer shift lever rod assembly.
6. DISCONNECT GROUND CABLE
Remove the bolt and disconnect the ground cable from the transfer.
7. REMOVE CROSSMEMBER
a. Support the transmission, as shown.
NOTICE: Use a wooden block so not to damage the transmission oil pan.
b. Remove the 8 bolts, 2 nuts and crossmember.
Torque:
Bolt: 50 Nm (510 kgf-cm, 37 ft. lbs.)
Nut: 74 Nm (750 kgf-cm, 54 ft. lbs.)
8. DISCONNECT BREATHER HOSE
HINT: At the time of installation, assemble the clip to the position shown in the illustration.
9. DISCONNECT NO.1 VEHICLE SPEED SENSOR, CENTER DIFFERENTIAL LOCK INDICATOR SWITCH, NEUTRAL POSITION SWITCH, L POSITION SWITCH AND MOTOR ACTUATOR CONNECTORS
10. JACK UP TRANSFER SLIGHTLY
Using a transmission jack, support the transfer.
11. REMOVE TRANSFER FROM TRANSMISSION
a. Disconnect the wire harness from the transfer.
b. Remove the 6 transfer adaptor rear mounting bolts.
Torque: 69 Nm (700 kgf-cm, 51 ft. lbs.)
c. Pull out the transfer down and toward the rear.
Installation
Installation is in the reverse order of removal.
1. APPLY MP GREASE TO TRANSFER ADAPTOR OIL SEAL
2. AFTER INSTALLATION, DO ROAD TEST
TRANSFER ASSEMBLY
Components
Disassembly
1. REMOVE BREATHER HOSE
2. REMOVE VEHICLE SPEED SENSOR DRIVEN GEAR
Remove the bolt, and driven gear.
Torque: 11 Nm (115 kgf-cm, 8 ft. lbs.)
3. REMOVE MOTOR ACTUATOR
Remove the 4 bolts and motor actuator.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)
HINT: At the time of reassembly, please refer to the following items.
- Set the motor actuator in differential lock condition.
- Apply FIPG to the motor actuator.
FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent
4. REMOVE OUTPUT GEAR FROM FRONT CASE
HINT: At the time of reassembly, apply gear oil to the output gear.
NOTICE: At the time of reassembly, do not turn the output gear.
5. REMOVE SCREW PLUG, SPRING AND BALL
a. Using a torx socket wrench (T40), remove the screw plug.
HINT: At the time of reassembly, apply liquid sealer to the screw plug threads.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 19 Nm (190 kgf-cm, 14 ft. lbs.)
b. Using a magnetic finger, remove the spring and ball.
6. REMOVE TRANSFER INDICATOR SWITCH Remove the center differential lock indicator switch, L position switch, neutral position switch and 3 gaskets.
Torque: 37 Nm (380 kgf-cm, 27 ft. lbs.)
7. REMOVE FRONT EXTENSION HOUSING
Remove the 6 bolts and front extension housing.
Torque: 37 Nm (380 kgf-cm, 27 ft. lbs.)
HINT: If necessary, tap the front extension housing lightly with a plastic hammer.
HINT: At the time of reassembly, please refer to the following items.
- Set the clutch sleeve in differential lock condition.
- Apply FIPG to the front extension housing.
FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent
8. REMOVE CLUTCH SLEEVE WITH SHIFT FORK NO.2 SHAFT AND SHIFT FORK NO.2
HINT: At the time of reassembly, make sure to install the clutch sleeve in the correct direction.
9. SEPARATE SHIFT FORK NO.2 SHAFT AND SHIFT FORK NO.2
a. Using 2 screwdrivers and a hammer, tap out the 3 snap rings from the shift fork No.2 shaft.
b. Separate the shift fork No.2 shaft and shift fork No.2.
10. REMOVE REAR EXTENSION HOUSING
Remove the 9 bolts and rear extension housing.
Torque: 37 Nm (380 kgf-cm, 27 ft. lbs.)
HINT: If necessary, tap the rear extension housing lightly with a plastic hammer.
HINT: At the time of reassembly, apply FIPG to the rear extension housing.
FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent
11. REMOVE ADJUSTING SHIM
HINT: At the time of installation, select adjusting shims for the idler gear rear taper roller bearing.
1) Using vernier calipers, measure dimension "A".
2) Lightly hold down the bearing outer race in the thrust direction to eliminate any looseness before making the measurement.
3) Using a steel straight edge and feeler gauge, measure the clearance of dimension "B".
4) Calculate the required thickness of the adjusting shim.
Thickness:
Dimension "A" + Dimension "B" + [0.022 - 0.049 mm, (0.0009 0.0019 inch)]
5) From the following table, select a shim so that its thickness is within the range of the calculation.
HINT: At the time of installation, select adjusting shims for the output shaft taper roller bearing.
6) Using a steel straight edge and feeler gauge, measure the clearance of dimension "C".
7) Lightly hold down the bearing outer race in the thrust direction to eliminate any looseness before making the measurement.
8) Calculate the required thickness of the adjusting shim.
Thickness:
Dimension "C" + [0.014 - 0.039 mm, (0.0006 - 0.0015 inch)]
9) From the table, select a shim so that its thickness is within the range of the calculation.
12. REMOVE OIL STRAINER FROM REAR CASE
Remove the 2 bolts and oil strainer.
Torque: 4.9 Nm (50 kgf-cm, 43 inch lbs.)
13. REMOVE CASE COVER
a. Remove the 5 bolts.
HINT: At the time of reassembly, apply liquid sealer to the bolt threads.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 37 Nm (380 kgf-cm, 27 ft. lbs.)
b. Using a brass bar and hammer, tap the case cover and remove it.
HINT: At the time of reassembly, apply FIPG to the rear case.
FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent
14. SEPARATE FRONT CASE AND REAR CASE
a. Using a snap ring expander, remove the snap ring from the rear case.
b. Remove the 8 bolts.
HINT: At the time of reassembly, apply liquid sealer to the "A" bolt threads.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 37 Nm (380 kgf-cm, 27 ft. lbs.)
c. Using a brass bar and hammer, tap the rear case and separate it.
HINT: At the time of reassembly, apply FIPG to the front case.
FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent
15. REMOVE 2 BEARING RACES FROM REAR CASE
16. REMOVE INPUT SHAFT ASSEMBLY
Using a plastic hammer, remove the input shaft assembly from the front case.
17. REMOVE IDLER GEAR ASSEMBLY WITH CENTER DIFFERENTIAL ASSEMBLY, SHIFT FORK NO.1 AND SHIFT FORK NO.1 SHAFT FROM FRONT CASE
NOTICE: At the time of reassembly, set the shift inner lever into the fork head part of the shift fork No.1 securely.
18. SEPARATE SHIFT FORK NO.1 AND SHIFT FORK NO.1 SHAFT
a. Using a pin punch and hammer, drive out the slotted spring pinch
b. Separate the shift fork No.1 and shift fork No.1 shaft.
19. REMOVE SHIFT OUTER LEVER AND INNER LEVER
a. Remove the nut and washer from the shift outer lever.
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)
b. Using a brass bar, hammer and socket wrench, tap out the lever lock pinch
c. Remove the shift outer lever, washer and inner lever from the front case.
20. IF NECESSARY, REPLACE INNER SHIFT LEVER OIL SEAL
a. Using a screwdriver, pry out the oil seal from the front case.
b. Apply MP grease to the lip of a new oil seal.
c. Using SST and a hammer, drive in a new oil seal.
SST 09950-60010 (09951-00270), 09950-70010 (09951-07150)
21. IF NECESSARY, REPLACE INPUT SHAFT OIL SEAL
a. Using SST and a hammer, drive out the oil seal.
SST 09316-60011 (09316-00011)
b. Apply MP grease to the lip of a new oil seal.
c. Using SST and a hammer, drive in a new oil seal.
SST 09316-60011(09316-00011,09316-00031)
22. REMOVE OIL RECEIVER FROM FRONT CASE
Remove the bolt"and oil receiver.
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)
23. REMOVE 2 BEARING RACES FROM FRONT CASE
a. Using SST, remove the bearing race (for the idler gear).
SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04060, 09957-04010), 09950-60010 (09951-00320)
HINT: At the time of reassembly, using SST and a press, install the bearing race (for the idler gear).
SST 09316-60011 (09316-00011, 09316-00031), 09950-60020(09951--00790)
b. Using a brass bar and hammer, remove the bearing race (for the output shaft).
HINT: At the time of reassembly, using SST and a press, install the bearing race (for the output shaft).
SST 09316-60011 (09316-00011, 09316-00031), 09950-60020(09951-00890)
24. INSPECT TRANSFER INDICATOR SWITCH
Check that continuity exists between the terminals, as shown.
25. INSPECT SHIFT FORK NO.2 AND CLUTCH SLEEVE CLEARANCE
Using a feeler gauge, measure the clearance between the shift fork No.2 and clutch sleeve.
Standard clearance:
0.1 - 0.4 mm (0.0039 - 0.0157 inch)
Maximum clearance:
0.4 mm (0.0157 inch)
Reassembly
Reassembly is in the reverse order of disassembly.
HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly.
INPUT SHAFT
Components
Disassembly
1. REMOVE REAR BALL BEARING
a. Using a snap ring expander, remove the snap ring.
b. Using a socket wrench and press, remove the rear ball bearing.
2. REMOVE FRONT BALL BEARING
a. Using a snap ring expander, remove the snap ring.
b. Using SST, remove the front ball bearing.
SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04010, 09957-04010, 09958-04010), 09950-60010 (09951-00400)
Reassembly
HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly.
1. INSTALL FRONT BALL BEARING
a. Using SST and a press, install a new front ball bearing.
SST 09316-60011 (09316-00011)
b. Select a snap ring that will allow the minimum axial play.
c. Using a snap ring expander, install a new snap ring.
2. INSTALL REAR BALL BEARING
a. Using SST and a press, install the rear ball bearing.
SST 09316-60011 (09316-00011, 09316-00031)
b. Select a snap ring that will allow the minimum axial play.
c. Using a snap ring expander, install a new snap ring.