Part 2
LF1A TRANSFER: TRANSFER ASSEMBLY: REASSEMBLY
6. INSTALL FORWARD CLUTCH DRAM OIL SEAL RING
Install the oil seal ring to the sleeve.
7. INSTALL TRANSFER COUNTER GEAR BEARING (for Front Transfer Case Side)
Using SST and a press, install a new bearing (outer race) to the front transfer case.
SST : 09950-60010
09951-00580
09951-00630
09952-06010
SST : 09950-60020
09951-00750
09951-00790
09952-06010
SST : 09950-70010
09951-07100
8. INSTALL TRANSFER COUNTER GEAR BEARING
for Front Transfer Case Side:
(1) Using SST and a press, install a new bearing (inner race) to the counter gear.
SST : 09316-60011
09316-00011
09613-22011
SST : 09950-60010
09951-00420
HINT
Disassemble SST (09613-22011) and only use the tube part.
for Rear Transfer Case Side:
(1) Using SST and a press, install a new bearing (inner race) to the counter gear.
SST : 09316-60011
09316-00011
SST : 09950-60010
09951-00420
9. ADJUST COUNTER GEAR BEARING PRELOAD
(a) Using a vernier caliper and precision straightedge, measure dimension A between the top surface of the front transfer case [*1] and the top surface of the counter gear bearing (outer race) [*2].
HINT
Perform the measurement at 3 locations at intervals of 120° around the circumference of the outer race and calculate the average.
NOTICE:
Perform the measurements with the idler gear assembly removed.
(b) Using a vernier caliper and precision straightedge, measure dimension B between the top surface of the rear transfer case [*1] and the surface which contacts the transfer counter gear shim [*2].
NOTICE:
Do not add the thickness of the precision straightedge.
(c) Using the formula below, calculate the thickness of the transfer counter gear shim and select an appropriate shim from the table.
Transfer counter gear shim thickness:
Dimension B - Dimension A
Transfer Counter Gear Shim Thickness:
Using SST and a press, install the shim and a new bearing (outer race) to the rear transfer case.
SST : 09950-60020
09951-00750
SST : 09950-70010
09951-07100
Install the counter gear to the front transfer case.
Install the rear transfer case with the 7 bolts to the front transfer case.
Torque : 27 Nm (275 kgf-cm, 20 ft-lbf)
Install the companion flange to the transfer assembly, and then 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.
Tighten the companion flange bolt.
Torque : 85 Nm (867 kgf-cm, 63 ft-lbf)
(d) Remove SST and turn the counter gear back and forth to settle the bearing.
Using a torque wrench, measure the turning torque of the counter gear bearing (counter gear preload).
Standard turning torque:
0.66 to 1.18 N*m (6.7 to 12.0 kgf*cm, 5.8 to 10.4 in.*lbf)
NOTICE:
Perform the measurements with the idler gear assembly removed.
HINT
Measure the turning torque while turning the counter gear at 60 rpm (1 rotation per second).
* If the turning torque is not as specified, replace the counter gear shim with one of a different thickness so that the measured value is within the standard range.
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.
Remove the 7 bolts from the rear transfer case.
(e) Remove the counter gear.
10. INSTALL TRANSFER OIL PUMP PLATE SUB-ASSEMBLY
(a) Install the drive rotor and driven rotor to the front transfer case.
(b) Install the plate pin to the oil pump plate.
(c) Install the plate to the front transfer case.
11. INSTALL TRANSFER IDLER GEAR BEARING (for Front Transfer Case Side)
Using SST and a press, install a new bearing (outer race) to the front transfer case.
SST : 09950-60020
09951-00890
SST : 09950-70010
09951-07100
12. INSTALL TRANSFER IDLER GEAR BEARING
for Front Transfer Case Side:
Using SST and a press, install a new bearing (inner race) to the idler gear.
SST : 09554-22010
for Rear Transfer Case Side:
Using SST and a press, install a new bearing (inner race) to the idler gear.
SST : 09950-60010
09951-00540
SST : 09554-22010
13. ADJUST TRANSFER IDLER GEAR BEARING PRELOAD
Install the counter gear to the front transfer case.
Install the idler gear to the front transfer case.
(a) Using a vernier caliper and precision straightedge, measure dimension A between the top surface of the front transfer case [*1] and the top surface of the idler gear bearing (outer race) [*2].
HINT
Perform the measurement at 3 locations at intervals of 120° around the circumference of the outer race and calculate the average.
(b) Using a vernier caliper and precision straightedge, measure dimension B between the top surface of the rear transfer case [*1] and the surface which contacts the transfer idler gear shim [*2].
NOTICE:
Do not add the thickness of the precision straightedge.
(c) Using the formula below, calculate the thickness of the transfer idler gear shim and select an appropriate shim from the table.
Transfer idler gear shim thickness:
Dimension B - Dimension A
Transfer Idler Gear Shim Thickness:
Using SST and a press, install the shim and a new bearing (outer race) to the rear transfer case.
SST : 09950-60020
09951-00780
09951-00890
09952-06010
SST : 09950-70010
09951-07100
Install the rear transfer case with the 7 bolts to the front transfer case.
Torque : 27 Nm (275 kgf-cm, 20 ft-lbf)
Install the companion flange to the transfer assembly, and then 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.
Tighten the companion flange bolt.
Torque : 85 Nm (867 kgf-cm, 63 ft-lbf)
(d) Remove SST and turn the idler gear back and forth to settle the bearing.
Using a torque wrench, measure the turning torque of the idler gear bearing (idler gear preload).
Standard turning torque:
1.54 to 2.64 N*m (15.7 to 26.9 kgf*cm, 13.6 to 23.4 in.*lbf)
NOTICE:
The measured turning torque for the idler gear preload is the combined preload of the idler gear and counter gear.
HINT
Measure the turning torque while turning the counter gear at 60 rpm (1 rotation per second).
* If the turning torque is not as specified, replace the idler gear shim with one of a different thickness so that the measured value is within the standard range.
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 form the transfer assembly.
(e) Remove the 7 bolts and rear transfer case from the front transfer case.
(f) Remove the idler gear and counter gear from the front transfer case.
14. INSTALL TRANSFER OIL COOLER RELIEF VALVE
Install the relief valve to the front transfer case.
Install the compression spring and valve plate to the front transfer case with the bolt.
Torque : 6.7 Nm (68 kgf-cm, 59 in-lbf)
NOTICE:
Be careful to prevent the relief valve compression spring from jumping out.
15. INSTALL NO. 1 TRANSFER OIL STRAINER
Install the oil strainer to the front transfer case.
16. INSTALL TRANSFER OIL SEPARATOR
Install the oil separator with the 3 bolts.
Torque : 7.0 Nm (71 kgf-cm, 62 in-lbf)