Part 2
TRANSFER ASSEMBLY
Disassembly and Assembly
INSPECTION AFTER DISASSEMBLY
Shift Rod Components
33. Remove the control valve assembly bolts.
34. Remove the control valve assembly.
CAUTION:
- Do not reuse any part that has been dropped or damaged.
- Make sure valve is assembled in the proper direction.
- Do not use a magnet because residual magnetism stays during disassembly.
35. Remove the lip seals from the center case.
CAUTION:
There are two kinds of lip seals (lip seal of large inner diameter: 5 pieces, lip seal of small inner diameter: 2 pieces).
Confirm the position before disassembly.
36. Disassemble the control valve assembly with the following procedure.
CAUTION:
- Do not reuse any part that has been dropped or damaged.
- Make sure valve is assembled in the proper direction.
- Do not use a magnet because residual magnetism stays during disassembly.
a. Remove all the bolts except for the two shown.
b. Remove the following from the control valve assembly:
- Clutch pressure solenoid valve
- Clutch pressure switch
- 2-4WD shift solenoid valve
- Line pressure switch
- Transfer fluid temperature sensor
c. Remove the O-rings from each solenoid valve, switch and terminal body.
d. Place the control valve with the lower body facing up. Remove the two bolts, and then remove the lower body and separator plate from the upper body.
CAUTION:
Do not drop relief balls. Detach lower body carefully.
e. Make sure the reverse balls, relief balls, relief springs, accumulator pistons and valve springs are securely installed as shown, and remove them.
f. Remove the retainer plates.
g. Remove each retainer plate (1), plug (2), control valve (3) and spring (4) from the upper body (5).
37. Remove the transfer motor bolts and motor from the center case. Then remove the O-ring from the transfer motor.
38. Remove the sub oil pump cover bolts.
39. Thread two bolts (M4 x 0.8) into the holes of sub oil pump cover as shown, and pull out to remove the sub oil pump assembly.
40. Remove the outer gear and inner gear from the sub oil pump housing.
41. Remove the oil filter bolts and oil filter.
CAUTION:
- Do not damage center case and oil filter.
- Loosen bolts and detach oil filter evenly.
42. Remove the O-rings (1) from the oil filter (2).
43. Remove the oil filter stud from the oil filter.
44. Remove the O-ring from the oil filter stud.
- Check the working face of the shift rod and fork for wear, partial wear, bending and other abnormality. If any is found, replace with a new one.
- Measure the clearance between the shift fork and sleeve. If it is out of specification, replace it with a new one.
Specification : Less than 0.36 mm (0.0142 in)
Planetary Carrier
- Measure the end play of each pinion gear. If it is out of specification, replace the planetary carrier assembly with a new one.
Pinion gear end play : 0.1 - 0.7 mm (0.004 - 0.028 in)
- Check the working face of each gear and bearing for damage, burrs, partial wear, dents and other abnormality. If any is found, replace the planetary carrier assembly with a new one.
Sun Gear
- Check if the oil passage of the sun gear assembly is clogged. For this, try to pass a 3.6 mm (0.142 in) dia. pin through the oil passage as shown.
- Check the sliding and contact surface of each gear and bearing for damage, burrs, partial wear, dents, and other abnormality. If any is found, replace the sun gear assembly with a new one.
Internal Gear
- Check the internal gear teeth for damage, partial wear, dents and other abnormality. If any is found, replace the internal gear with a new one.
Gears and Drive Chain
- Check the gear faces and shaft for wear, cracks, damage, and seizure.
- Check the surfaces which contact the sun gear, clutch drum, clutch hub, press flange, clutch piston and each bearing for damage, peel, partial wear, dents, bending, or other abnormal damage. If any is found, replace with a new one.
Bearing
- Make sure the bearings roll freely and are free from noise, pitting and cracks.
Main Oil Pump
1. Check the inner and outer circumference, tooth face, and side face of the inner and outer gears for damage or abnormal wear.
2. Measure the side clearance between the main oil pump housing edge and the inner and outer gears.
3. Make sure the side clearance is within specification. If the measurement is out of specification, replace the inner and outer gears with new ones as a set. Refer to Assembly.
Specification : 0.015 - 0.035 mm (0.0006 - 0.0014 in)
Sub-oil Pump
1. Check the inner and outer circumference, tooth face, and side face of the inner and outer gears for damage or abnormal wear.
2. Measure the side clearance between the sub oil pump housing edge and the inner and outer gears.
3. Make sure the side clearance is within specification. If the measurement is out of specification, replace the inner and outer gears with new ones as a set. Refer to Inspection And Adjustment.
Specification : 0.015 - 0.035 mm (0.0006 - 0.0014 in)
Control Valve
- Check resistance between the terminals of the clutch pressure solenoid valve, 2-4WD shift solenoid valve, clutch pressure switch, line pressure switch and the transfer fluid temperature sensor. Refer to P1822 (clutch pressure solenoid valve), P1823 (2-4WD solenoid valve), P1827 (clutch pressure switch) P1828 (line pressure switch) and P1826 (transfer fluid temperature sensor).
- Check the sliding faces of the control valves and plugs for abnormality. If any is found, replace the control valve assembly with a new one. Refer to Assembly.
CAUTION:
Replace control valve body together with clutch return spring as a set.
- Check each control valve spring for damage or distortion. Also check its free length, outer diameter and wire diameter. If any damage or fatigue is found, replace the control valve body with a new one. Refer to Assembly.
CAUTION:
Replace control valve body together with clutch return spring as a set.
Clutch
- Check the drive plate facings and driven plate for damage, cracks or other abnormality. If any abnormalities are found, replace with a new one.
- Check the thickness of the drive plate facings and driven plate. Refer to Inspection And Adjustment.
CAUTION:
- Measure facing thickness at 3 points to take an average.
- Check all drive and driven plates.
- Check return spring for damage or deformation.
- Do not remove spring from plate.
Return Spring
- Check the stamped mark shown. Then, check that the free lengths, (include thickness of plate) are within specifications. If any abnormality is found, replace with a new return spring assembly of the same stamped number. Refer to Inspection And Adjustment.