Assembly

TRANSFER CASE

Assembly

1.Install the oil defense to transfer cover.
2.Install gaskets onto filler plug and drain plug and install them into transfer case.

CAUTION:
- Never reuse gasket.
- Install filler plug after oil is filled.
3.Install the dowel pin to transfer case.

CAUTION:
Never reuse the dowel pin.
4.Select drive pinion adjusting shim, and install it to transfer case. Adjustment.





5.Install outer race of pinion bearing (front) to the transfer case with the drift (A) [SST: ST-37830000 (-)].

CAUTION:
- Never reuse pinion bearing.
- Apply gear oil to the pinion bearing.





6.Install outer race of pinion bearing (rear) to transfer case with the drift (A) [SST: ST-33230000 (J-25805-01)].

CAUTION:
- Never reuse pinion bearing.
- Apply gear oil to the pinion bearing.
7.Install drive pinion assembly to transfer case. Assembly.
8.Install ring gear shaft assembly to transfer case. Assembly.





9.Set the drifts (A and B) to right and left side spacers individually. Compress ring gear shaft assembly with ring gear bearing to install transfer cover to transfer case.

A : Drift (Commercial service tool)
B : Drift (Commercial service tool)

CAUTION:
- Never apply gasket fluid on the mounting surface.
- Clean the mounting surface of transfer case and transfer cover to degrease sufficiently.
- The drift shall be placed on the center of the spacers.
- The pressure shall be as low as to install ring gear shaft assembly into transfer case. The maximum pressure shall be 10 kN (1 ton, 1.0 Imp ton).
- If the adjusting shims and spacers are installed by tapping, the transfer cover may be damaged.
Avoid tapping.
10.Check backlash, tooth contact, and total preload. Adjustment.

CAUTION:
Measure the total preload without the transfer case oil seals.
11.Remove transfer cover. Disassembly.





12.Apply liquid gasket (1) to mating surface of transfer cover.
- Use Genuine Silicone RTV or equivalent. Recommended Chemical Products And Sealants.

CAUTION:
- Remove old gasket adhering to the mounting surfaces.
Also remove any moisture, oil, or foreign material adhering to the mounting surfaces.
- The width of sealant bend is 2 - 3 mm (0.08 - 0.012 in).
- Overlap both ends of the bead for at least 3 mm (0.012 in).
- Immediately install transfer cover after installing applying gasket.





13.Set the drifts (A and B) to right and left side spacers individually.
Compress ring gear shaft assembly with ring gear bearing to install transfer cover to transfer case.

A : Drift (Commercial service tool)
B : Drift (Commercial service tool)

CAUTION:
- Immediately install after applying gasket.
- The drift shall be placed on the center of the spacers.
- The pressure shall be as low as to install ring gear shaft assembly into transfer case. The maximum pressure shall be 10 kN (1 ton, 1.0 Imp ton).
- If the adjusting shims and spacers are installed by tapping, the transfer cover may be damaged.
Avoid tapping.
14.Tighten transfer cover mounting bolts to the specified torque.





15.Using the drifts (A and B), install transfer case oil seal (left) (1)
within the dimension (L) shown as follows.

A : Drift (Commercial service tool)
B : Drift [SST: ST27863000 ( - )]

L: 1.0 - 1.6 mm (0.040 - 0.063 in)

CAUTION:
- Never reuse oil seals.
- When installing, never incline oil seals.
- Apply multi-purpose grease onto oil seal lips, and gear oil onto the circumference of oil seal.
- Immediately install after installing transfer cover.
- After installing oil seal, immediately wipe out gasket squeezed out inward of transfer case.





16.Using the drifts (A) [SST: ST-35271000 (J-26091)], install transfer case oil seal (right) (1) within the dimension (L) shown as follows.

L: 0 - 0.6 mm (0 - 0.024 in)

CAUTION:
- Never reuse oil seals.
- When installing, never incline oil seals.
- Apply multi-purpose grease onto oil seal lips, and gear oil onto the circumference of oil seal.
- Immediately install after installing transfer cover.
- After installing oil seal, immediately wipe out gasket squeezed out inward of transfer case.