From 08/2009
MF1A TRANSFER / 4WD / AWD: TRANSFER ASSEMBLY: DISASSEMBLY
1. REMOVE TRANSFER AND TRANSAXLE SETTING STUD BOLT
(a) Remove the 4 transfer and transaxle setting stud bolts.
2. REMOVE NO. 2 TRANSFER CASE PLUG
(a) Remove the No. 2 transfer case plug.
(b) Remove the gasket from the No. 2 transfer case plug.
3. REMOVE NO. 1 TRANSFER CASE PLUG
(a) Remove the No. 1 transfer case plug.
(b) Remove the gasket from the No. 1 transfer case plug.
4. REMOVE TRANSFER DRAIN PLUG
(a) Remove the transfer drain plug.
(b) Remove the gasket from the transfer drain plug.
5. REMOVE TRANSFER CASE BREATHER PLUG
(a) Using a screwdriver, remove the transfer case breather plug.
6. REMOVE TRANSFER CASE COVER SUB-ASSEMBLY
(a) Remove the 8 bolts.
(b) Using a brass bar and a hammer, remove the transfer case cover sub-assembly from the transfer case.
NOTICE:
Place the brass bar on the rib protruding from the case.
7. REMOVE BREATHER OIL DEFLECTOR
(a) Remove the bolt and breather oil deflector.
8. REMOVE TRANSFER DYNAMIC DAMPER
(a) Remove the 3 bolts and transfer dynamic damper from the transfer extension housing sub-assembly.
9. REMOVE TRANSFER CASE STRAIGHT PIN
(a) Remove the 4 transfer case straight pins from the transfer case.
10. SECURE TRANSFER ASSEMBLY
(a) Attach the transfer assembly to the overhaul attachment.
11. 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.
12. REMOVE TRANSFER CASE REAR OIL SEAL
(a) Using SST, remove the transfer case rear oil seal from the transfer extension housing sub-assembly.
SST : 09308-00010
NOTICE:
Be careful not to damage the oil seal contact surface or the inside surface of the oil seal.
13. 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.
14. INSPECT PRELOAD MF1A Transfer Case
15. INSPECT RING GEAR BACKLASH MF1A Transfer Case
16. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVEN PINION MF1A Transfer Case
17. REMOVE TRANSFER CASE FRONT OIL SEAL
(a) Using SST, remove the transfer case front oil seal from the transfer case.
SST : 09308-00010
NOTICE:
Do not damage the oil seal contact surface on the case.
18. REMOVE TRANSFER CASE FRONT OIL SEAL (for RH Side)
(a) Using SST, remove the transfer case front oil seal from the transfer case.
SST : 09308-00010
NOTICE:
Do not damage the oil seal contact surface on the case.
19. REMOVE BEARING CAP
(a) Remove the 2 bolts and bearing cap.
20. REMOVE NO. 1 TRANSFER OUTPUT SHAFT SPACER
(a) Using SST, a screwdriver and a hammer, remove the No. 1 transfer output shaft spacer.
Text in Illustration
SST : 09504-22011
NOTICE:
Do not damage the transfer case.
21. REMOVE NO. 2 TRANSFER RING GEAR MOUNTING CASE WASHER
22. REMOVE TRANSFER RING GEAR MOUNTING CASE
(a) Remove the transfer ring gear mounting case from the transfer case.
23. REMOVE DRIVEN PINION
(a) Using SST and a hammer, unstake the gear nut.
SST : 09930-00010
HINT
* Use SST with the flat side facing outward.
* Do not machine the tip of SST with a grinder, etc.
(b) Using SST, remove the gear nut.
Text in Illustration
SST : 09326-20011
SST : 09556-16030
(c) Using a press, press out the driven pinion, transfer driven pinion rear bearing (inner race) and transfer pinion bearing spacer.
NOTICE:
* Place a piece of cloth under the transfer case to prevent the driven pinion from dropping out of the bearing.
* Use wooden blocks or similar objects under the case to keep it level.
24. REMOVE TRANSFER DRIVEN PINION FRONT BEARING
(a) Using SST and a press, press out the transfer driven pinion front bearing (inner race).
SST : 09950-00020
(b) Using a brass bar and a hammer, tap the 2 positions shown in the illustration on the driven pinion front bearing (outer race) to remove it from the case.
25. REMOVE TRANSFER OUTPUT SHAFT WASHER
(a) Remove the transfer output shaft washer.
26. REMOVE RING GEAR MOUNTING CASE BEARING
(a) Remove the ring gear mounting case bearing (outer race) RH from the transfer ring gear mounting case.
(b) Using SST, remove the ring gear mounting case bearing (inner race) RH from the transfer ring gear mounting case.
Text in Illustration
SST : 09950-40011
09951-04010
09952-04010
09953-04020
09954-04010
09955-04061
09957-04010
09958-04011
SST : 09950-60010
09951-00440
NOTICE:
Use SST (09953-04020) after applying grease to its threads and tip.
(c) Using SST, remove the ring gear mounting (inner race) LH from the transfer ring gear mounting case.
Text in Illustration
SST : 09950-40011
09951-04010
09952-04010
09953-04020
09954-04010
09955-04061
09957-04010
09958-04011
SST : 09950-60010
09951-00400
NOTICE:
Use SST (09953-04020) after applying grease to its threads and tip.
(d) Using a brass bar and a hammer, tap the 2 positions shown in the illustration on the ring gear mounting case bearing (outer race) LH to remove it from the transfer case.
(e) Remove the ring gear mounting case plate washer.
27. INSPECT RUNOUT OF RING GEAR MF1A Transfer Case
28. REMOVE RING GEAR
(a) Put matchmarks on the transfer ring gear mounting case and ring gear.
Text in Illustration
(b) Remove the 12 bolts.
(c) Using a plastic hammer, tap on the ring gear to separate it from the transfer ring gear mounting case.
NOTICE:
Do not damage the ring gear teeth.
29. INSPECT TRANSFER RING GEAR MOUNTING CASE MF1A Transfer Case
30. REMOVE TRANSFER DRIVEN PINION REAR BEARING
(a) Using a brass bar and a hammer, tap the 2 positions shown in the illustration on the driven pinion rear bearing (outer race) to remove it from the transfer case.
