Disassembly

UF1AE TRANSFER: TRANSFER ASSEMBLY: DISASSEMBLY

1. REMOVE TRANSFER OIL PAN

(a) Remove the 9 bolts.





(b) Insert the blade of an oil pan seal cutter between the transfer oil pan and transfer case. Cut through the sealer and remove the transfer oil pan.





NOTICE:
Do not damage the contact surface of the transfer oil pan.

(c) Remove the transfer oil cleaner magnet from the transfer oil pan.





NOTICE:
* Clean the inside of the oil pan thoroughly, removing all metal shavings, sludge and any other foreign objects.
* Remove any metal shavings from the magnet.

2. REMOVE TRANSFER VALVE BODY ASSEMBLY

(a) Remove the 4 bolts and the transfer valve body assembly.





(b) Disconnect the transfer wire connector from the transfer control solenoid.

(c) Remove the bolt and the transfer wire.





3. REMOVE TRANSFER EXTENSION HOUSING DUST DEFLECTOR

(a) Using SST, remove the transfer extension housing dust deflector.





SST : 09950-40011

09951-04010

09952-04010

09953-04020

09954-04010

09955-04051

09958-04011

NOTICE:
Apply grease to the threads and tip of the SST center bolt before use.

4. REMOVE TRANSFER CASE

(a) Remove the 8 bolts and clamp.





(b) Using a plastic hammer, tap the transfer case to remove it.





5. REMOVE TRANSFER REAR OUTPUT SHAFT ASSEMBLY

(a) Remove the transfer rear output shaft assembly.





6. REMOVE FLANGE YOKE

(a) Using SST and a hammer, release the staked part of the nut.





SST : 09930-00010

NOTICE:
* Be sure to use the SST with the tapered surface facing the shaft.
* Do not grind the tip of the SST with a grinder etc.
* Completely loosen the staked part of the nut when removing it.
* Do not damage the threads of the transfer drive sprocket.

(b) Using SST, hold the yoke.





SST : 09330-00021

SST : 09213-54015

(c) Using a deep socket wrench (30 mm), remove the nut.

(d) Remove the flange yoke.

7. REMOVE TRANSFER CHAIN CASE REAR

(a) Remove the 10 bolts.





(b) Tap the 3 protrusions of the transfer chain case gently with a brass bar and hammer to loosen, and remove it.





NOTICE:
Do not damage the transfer chain case.

8. REMOVE TRANSFER FRONT DRIVE CHAIN, TRANSFER DRIVE SPROCKET ASSEMBLY AND TRANSFER FRONT DRIVEN CLUTCH SLEEVE ASSEMBLY

(a) Remove the transfer front drive chain, transfer drive sprocket and transfer front driven clutch sleeve.





(b) Remove the transfer front drive chain from the transfer drive sprocket and transfer front driven clutch sleeve.

9. REMOVE TRANSFER CHAIN CASE FRONT

(a) Remove the 6 bolts and transfer chain case front.





HINT
If necessary, tap the transfer chain case front with a plastic hammer to loosen and remove it.

10. REMOVE TRANSFER CASE REAR OIL SEAL

(a) Using a screwdriver with its tip taped, pry out the oil seal from the transfer case.





(b) Remove the bolt and clamp.





11. REMOVE TRANSFER CASE BEARING

(a) Using SST, remove the transfer case bearing from the transfer case.





SST : 09308-00010

12. REMOVE TRANSFER BAFFLE VALVE SUB-ASSEMBLY

(a) Remove the bolt and transfer baffle valve from the transfer chain case rear.





13. REMOVE TRANSFER CHAIN CASE GOVERNOR APPLY GASKET

(a) Remove the screw, O-ring, and 2 gaskets from the transfer chain case front.





(b) Remove the 2 gaskets from the transfer chain case rear.





14. REMOVE TRANSFER CASE FRONT OIL SEAL

(a) Using a screwdriver with its tip taped, pry out the oil seal from the transfer chain case front.





15. REMOVE TRANSFER REAR OUTPUT SHAFT AND CENTER DIFFERENTIAL CARRIER

(a) Remove the transfer rear output shaft and center differential carrier from the transfer direct clutch drum.





16. REMOVE TRANSFER REAR OUTPUT SHAFT BEARING

(a) Remove the transfer rear output shaft bearing from the transfer direct clutch drum.





17. INSPECT CENTER DIFFERENTIAL CARRIER ASSEMBLY

(a) Using a feeler gauge, measure the center differential carrier pinion gear thrust clearance.





Standard clearance:

0.2 to 0.5 mm (0.008 to 0.020 in.)

If the clearance is greater than the standard clearance, replace the center differential carrier.

18. REMOVE CENTER DIFFERENTIAL CLUTCH DISC SET

(a) Using a screwdriver with its tip taped, remove the snap ring from the transfer direct clutch drum.





(b) Remove the 2 center differential clutch disc flanges and center differential clutch disc set from the transfer direct clutch drum.





HINT
* A: Center differential clutch disc flange (No.1)
* B: Center differential clutch disc set (Discs)
* C: Center differential clutch disc set (Plates)
* D: Center differential clutch disc flange (No.2)

19. INSPECT CENTER DIFFERENTIAL CLUTCH DISC SET

(a) Check whether the sliding surfaces of the disc and flange are worn or burnt.





If necessary, replace them.

NOTICE:
* If the lining of the disc is peeled off or discolored, or if any part of the printed numbers is damaged, replace all discs.
* Before assembling new discs, soak them in ATF for at least 15 minutes.

20. REMOVE CENTER DIFFERENTIAL CLUTCH PRESSURE BALANCER

(a) Place SST on the center differential clutch pressure balancer, and compress the return spring with a press.





SST : 09350-30020

09350-07040

(b) Using SST, remove the snap ring.

SST : 09350-30020

09350-07040

09350-07070

(c) Remove the center differential clutch pressure balancer from the transfer direct clutch drum.





21. REMOVE TRANSFER DIRECT CLUTCH RETURN SPRING ASSEMBLY

(a) Remove the transfer direct clutch return spring from the transfer direct clutch drum.





22. INSPECT TRANSFER DIRECT CLUTCH RETURN SPRING ASSEMBLY

(a) Using vernier calipers, measure the free length of the spring together with the spring seat.





Standard free length:

15.2 to 15.8 mm (0.5984 to 0.6220 in.)

If the free length is shorter than the standard free length, replace the transfer direct clutch return spring.

23. REMOVE CENTER DIFFERENTIAL CLUTCH PISTON

(a) Install the transfer direct clutch drum to the transfer center support.





(b) While pushing down evenly on the center differential clutch piston, apply air (200 kpa, 2.0 kgf*cm2, 19 psi), at the oil hole on the transfer chain case rear as shown in the illustration, to remove the center differential clutch piston from the transfer direct clutch drum.





(c) Remove the direct clutch drum from the transfer center support.

24. REMOVE TRANSFER DIRECT CLUTCH PISTON O-RING

(a) Remove the 2 O-rings from the center differential clutch piston.





25. INSPECT TRANSFER DIRECT CLUTCH DRUM

(a) Using a cylinder gauge, measure the inside diameter of the transfer direct clutch drum.





Standard inside diameter:

65.00 to 65.06 mm (2.559 to 2.564 in.)

If the inside diameter is greater than the standard inside diameter, replace the transfer direct clutch drum.

26. REMOVE TRANSFER CENTER SUPPORT

(a) Remove the 5 bolts and transfer center support.





(b) Remove the 2 screws and 2 O-rings from the transfer chain case rear.

27. REMOVE TRANSFER CENTER SUPPORT SEAL RING

(a) Remove the 2 transfer center support seal rings from the transfer center support.





28. INSPECT TRANSFER CENTER SUPPORT

(a) Using a cylinder gauge, measure the inside diameter of the transfer center support.





Standard inside diameter:

49.9 to 50.1 mm (1.965 to 1.972 in.)

If the inside diameter is greater than the standard inside diameter, replace the transfer center support.

29. REMOVE TRANSFER DRIVEN SPROCKET BEARING

(a) Using SST and a press, remove the transfer driven sprocket bearing from the transfer front driven clutch sleeve.





SST : 09950-00020

(b) Using SST and a press, remove the transfer driven sprocket bearing from the transfer front driven clutch sleeve.





SST : 09950-60010

09951-00530

SST : 09950-70010

09951-07100

30. REMOVE TRANSFER DRIVE SPROCKET BEARING

(a) Using SST and a press, remove the transfer drive sprocket bearing from the transfer drive sprocket.





SST : 09950-00020

SST : 09950-70010

09951-07100

SST : 09950-60010

09951-00480

(b) Using SST and a press, remove the transfer drive sprocket bearing from the transfer drive sprocket.





SST : 09950-00020

SST : 09950-70010

09951-07100

SST : 09950-60010

09951-00550

31. REMOVE TRANSFER CONTROL SOLENOID

(a) Remove the bolt, solenoid lock plate and transfer control solenoid.





32. REMOVE TRANSFER VALVE BODY COVER

(a) Remove the 6 bolts.





(b) Remove the transfer valve body cover and transfer valve body plate upper from the transfer upper valve body.





(c) Remove the solenoid oil strainer from the transfer valve body cover.

33. REMOVE TRANSFER SOLENOID MODULATOR VALVE

(a) While pushing on the transfer modulator valve plug, remove the transfer solenoid modulator valve plug seat from the transfer upper valve body.





(b) Remove the transfer solenoid modulator valve plug, transfer solenoid modulator valve and low-high shift valve compression spring from the transfer upper valve body.





34. REMOVE CENTER DIFFERENTIAL CLUTCH CONTROL VALVE

(a) While pushing on the center differential clutch control valve plug, remove the center differential clutch control valve plug seat from the transfer upper valve body.





(b) Remove the center differential clutch control valve plug, center differential clutch control valve, transfer direct clutch modulator valve spring and center differential clutch control valve sleeve from the transfer upper valve body.