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Disassembly





LF1A TRANSFER: TRANSFER ASSEMBLY: DISASSEMBLY

1. REMOVE DYNAMIC DAMPER





Remove the bolt, 2 washers and damper from the rear transfer case.

2. REMOVE TRANSFER CASE PLUG





Using a 6 mm hexagon socket wrench, remove the 2 case plugs and 2 O-rings from the front transfer case.

3. REMOVE FILLER PLUG





Using a 10 mm hexagon socket wrench, remove the filler plug and gasket from the rear transfer case.

4. REMOVE TRANSFER DRAIN PLUG





Using a 10 mm hexagon socket wrench, remove the drain plug and O-ring from the front transfer case.

5. REMOVE TRANSFER CASE BREATHER PLUG





Remove the breather plug from the front transfer case.

6. REMOVE NO. 2 TRANSFER CASE PLUG





Using a 17 mm straight hexagon wrench, remove the case plug and gasket from the rear transfer case.

7. REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY





Using SST, hold the companion flange in place.

SST : 09213-58013

SST : 09330-00021

HINT
Use bolts of size M8 x P1.25 with a length of approximately 55 mm (2.16 in.) or equivalent to secure the companion flange.





Remove the companion flange bolt and companion flange from the transfer assembly.

8. REMOVE DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY





Using SST and a hammer, loosen the staked part of the transfer output shaft nut.

SST : 09930-00010

NOTICE:
* Completely loosen the staked part of the transfer output shaft nut.
* Do not damage the threads of the No. 1 differential case.
* Use SST with the tapered surface facing the No. 1 differential case.
* Do not grind the end of SST with a grinder or other tool.





Using SST, hold the companion flange in place.

SST : 09330-00021

SST : 09950-30012

09955-03040

(a) Using a 30 mm socket wrench, remove the transfer output shaft nut.





Using SST, remove the companion flange.

SST : 09950-30012

09951-03010

09953-03010

09954-03010

09955-03040

9. REMOVE TRANSFER EXTENSION HOUSING OIL SEAL





Using SST, remove the oil seal.

SST : 09308-00010

NOTICE:
Be careful not to damage the surface of the transfer extension housing that contacts the oil seal.

10. REMOVE NO. 1 DIFFERENTIAL CASE HOLE SNAP RING





Using needle-nose pliers, remove the snap ring from the extension housing.

11. REMOVE TRANSFER EXTENSION HOUSING





Remove the 11 bolts and bracket.





Using an oil pan seal cutter, remove the extension housing.

NOTICE:
Be careful not to damage the contact surface of the extension housing or rear transfer case.

12. REMOVE NO. 1 TRANSFER THRUST BEARING RACE





Using a screwdriver, remove the bearing race from the extension housing.

HINT
Tape the screwdriver tip before use.

NOTICE:
Be careful not to damage the surface which contacts the bearing race.

13. REMOVE TRANSFER OUTPUT SHAFT CYLINDRICAL ROLLER BEARING





Using SST and a press, remove the bearing (outer race) from the extension housing.

SST : 09950-60010

09951-00460

SST : 09950-70010

09951-07100

HINT
The bearing (inner race) is removed from the No. 1 differential case sub-assembly.

14. REMOVE TRANSFER OUTPUT SHAFT WASHER





Remove the 2 shaft washers from the No. 1 differential case.

15. REMOVE DIFFERENTIAL CASE NEEDLE ROLLER BEARING





Remove the bearing from the No. 1 differential case.

16. REMOVE NO. 2 TRANSFER THRUST BEARING RACE





Remove the bearing race from the No. 1 differential case.

17. REMOVE TRANSFER OUTPUT SHAFT SHIM





Remove the shim from the No. 1 differential case.

18. REMOVE NO. 1 DIFFERENTIAL CASE SUB-ASSEMBLY

(a) Remove the No. 1 differential case from the rear transfer case.

19. REMOVE TRANSFER OUTPUT SHAFT CYLINDRICAL ROLLER BEARING





Using SST, remove the bearing (inner race) from the No. 1 differential case.

SST : 09950-00020

SST : 09950-00030

20. REMOVE BREATHER OIL DEFLECTOR





Remove the 2 bolts and oil deflector.

21. REMOVE TRANSFER INPUT GEAR STOPPER SHAFT SNAP RING





Using a snap ring expander, remove the snap ring from the input shaft.

22. REMOVE TRANSFER INPUT GEAR STOPPER





Remove the gear stopper from the input shaft.

23. REMOVE REAR TRANSFER CASE





Remove the 7 bolts and rear transfer case.

24. REMOVE TRANSFER IDLER GEAR ASSEMBLY





Remove the idler gear from the front transfer case.

25. REMOVE TRANSFER OIL PUMP DRIVE SHAFT





Remove the oil pump drive shaft from the front transfer case.

26. REMOVE TRANSFER COUNTER GEAR ASSEMBLY





Remove the counter gear from the front transfer case.

27. REMOVE TRANSFER FRONT DRIVE GEAR ASSEMBLY





Remove the drive gear from the front transfer case.

28. REMOVE TRANSFER FRONT DRIVE GEAR PIN





Remove the drive gear pin from the front transfer case.

29. REMOVE TRANSFER INPUT SHAFT





Remove the input shaft from the drive gear.

30. REMOVE TRANSFER OIL SEAL RING





Remove the oil seal ring from the input shaft.

31. REMOVE DRIVE PINION COMPANION FLANGE OIL SEAL





Using a screwdriver and hammer, tap out the oil seal from the companion flange.

HINT
Tape the screwdriver tip before use.

32. REMOVE TRANSFER IDLER GEAR BEARING





for Front Transfer Case Side:

Using SST, remove the idler gear bearing (inner race) from the idler gear.

SST : 09950-40011

09951-04020

09952-04010

09953-04030

09954-04010

09955-04021

09957-04010

09958-04011

SST : 09950-60010

09951-00420

09951-00540

09952-06010





for Rear Transfer Case Side:

Using SST, remove the idler gear bearing (inner race) from the idler gear.

SST : 09950-40011

09951-04020

09952-04010

09953-04030

09954-04010

09955-04021

09957-04010

09958-04011

SST : 09950-60010

09951-00440

09951-00540

09952-06010

33. REMOVE TRANSFER COUNTER GEAR BEARING





for Front Transfer Case Side:

Using SST, remove the counter gear bearing (inner race) from the counter gear.

SST : 09950-00020

SST : 09950-00030

SST : 09950-40011

09957-04010

SST : 09950-60010

09951-00280

09951-00440

09952-06010





for Rear Transfer Case Side:

Using SST, remove the counter gear bearing (inner race) from the counter gear.

SST : 09950-00020

SST : 09950-00030

SST : 09950-40011

09957-04010

SST : 09950-60010

09951-00360

09951-00500

09952-06010

34. REMOVE TRANSFER OIL SEPARATOR





Remove the 3 bolts and oil separator from the front transfer case.

35. REMOVE NO. 1 TRANSFER OIL STRAINER





Remove the oil strainer from the front transfer case.

36. REMOVE TRANSFER OIL COOLER RELIEF VALVE





Remove the bolt, relief valve plate and relief valve compression spring from the front transfer case.

NOTICE:
Be careful to prevent the relief valve compression spring from jumping out.





Using a magnet hand, remove the relief valve from the front transfer case.

37. REMOVE TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL





Using a screwdriver and hammer, tap out the oil seal from the front transfer case.

NOTICE:
Be careful not to damage the surface which contacts the oil seal.

38. REMOVE TRANSFER IDLER GEAR BEARING





for Front Transfer Case Side:

Using SST, remove the idler gear bearing (outer race) from the front transfer case.

SST : 09950-40011

09951-04020

09952-04010

09953-04030

09954-04010

09955-04071

09957-04010

SST : 09950-60010

09951-00290





for Rear Transfer Case Side:

Using SST, remove the idler gear bearing (outer race) from the rear transfer case.

SST : 09950-40011

09951-04020

09952-04010

09953-04030

09954-04010

09955-04071

09957-04010

SST : 09950-60010

09951-00380

(a) Remove the idler gear shim from the rear transfer case.

39. REMOVE TRANSFER OIL PUMP PLATE SUB-ASSEMBLY

(a) Using an air gun, gradually apply air and remove the transfer oil pump plate from the front transfer case.

(b) Remove the transfer oil pump plate pin from the transfer oil pump plate.

(c) Remove the drive rotor and driven rotor from the front transfer case.

40. REMOVE TRANSFER COUNTER GEAR BEARING





for Front Transfer Case Side:

(1) Using SST, remove the bearing (outer race) from the front transfer case.

SST : 09612-65014

09612-01020





for Rear Transfer Case Side:

(1) Using SST, remove the bearing (outer race) from the rear transfer case.

SST : 09950-40011

09951-04020

09952-04010

09953-04030

09954-04010

09955-04071

09957-04010

SST : 09950-60010

09951-00420

(a) Remove the counter gear shim from the rear transfer case.

41. REMOVE FORWARD CLUTCH DRAM OIL SEAL RING





Remove the oil seal ring from the sleeve.

42. REMOVE TRANSFER FRONT CASE OIL SEAL





Using a screwdriver, pry out the oil seal from the front transfer case.

NOTICE:
Be careful not to damage the surface which contacts the oil seal.

HINT
Tape the screwdriver tip before use.

43. REMOVE TRANSFER FRONT DRIVE GEAR CYLINDRICAL ROLLER BEARING (for Front Transfer Case Side)





Using a screwdriver, remove the bearing rollers and roller cage.





Remove the drive gear bearing and race from the front transfer case.





Using SST, remove the bearing from the front transfer case.

SST : 09649-17010

SST : 09950-40011

09951-04010

09952-04010

09953-04020

09954-04010

09955-04041

09957-04010

44. REMOVE TRANSFER OUTPUT SHAFT CYLINDRICAL ROLLER BEARING (for Rear Transfer Case Side)





Using needle-nose pliers, remove the snap ring from the rear transfer case.





Using SST and a press, remove the bearing from the rear transfer case.

SST : 09950-60010

09951-00540

09951-00650

09952-06010

SST : 09950-70010

09951-07100

NOTICE:
Be careful of the straight pins when placing the case on the press.

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