Transfer Clutch
Transfer ClutchREMOVAL
1. Remove the transmission assembly from vehicle.
2. Remove the extension case, and then remove the transfer clutch.
INSTALLATION
1. Select the rear drive shaft shim.
2. Select the driven plate No. 3.
3. Install the extension case and intermediate case.
4. Install the transmission assembly into vehicle.
INSPECTION
^ Inspect the drive plate facing for wear and damage.
^ Inspect the snap ring for wear; return spring for permanent distortion, breakage and deformation.
^ Check that the D-ring is not damaged.
^ Inspect the extension end play and adjust it to within specifications.
ADJUSTMENT
SELECTION OF REAR DRIVE SHAFT SHIM
1. Insert the rear drive shaft into the reduction drive gear and center differential assembly.
2. Using the ST, measure the depth A, which is from mating surface of extension case to ball bearing outer ring contact surface.
ST 398643600 GAUGE
3. Using the ST, measure the height B from the intermediate case mating surface to ball bearing outer ring contact surface. ST 398643600 GAUGE
4. Calculation formula:
When clearances are 0.05 mm (0.0020 inch):
T (mm) = A- (B - 0.28) - 0.05
[T (in) = A - (B - 0.011) - 0.0020]
When clearances are 0.25 mm (0.0098 inch):
T (mm) = A- (B - 0.28) - 0.25
[T (in) = A - (B - 0.011) - 0.0098]
Specification: 0.05-0.25 mm (0.0020-0.0098 inch)
A: Depth from end of extension case to ball bearing outer ring contact surface
B: Height from end of intermediate case to ball bearing outer ring contact surface T: Shim thickness
NOTE: Calculation formula for "T" is applied when measuring using ST (398643600 GAUGE). When not using ST, apply following.
When clearances are 0.05 mm (0.0020 inch):
T (mm) = (A - a) - (B - p) - 0.28) - 0.05
[T (in) = (A - a) - (B - p) - 0.011) - 0.0020]
When clearances are 0.25 mm (0.0098 inch):
T (mm) = (A - a) - (B - p) - 0.28) - 0.25
[T (in) = (A - a) - (B - p) - 0.011) - 0.0098]
T: Shim thickness
A: Depth from end of extension case to ball bearing outer ring contact surface
B: Height from end of intermediate case to ball bearing outer ring contact surface
a: Collar thickness used when measuring "A"
b: Collar thickness used when measuring "B"
0.28 (0.011): Gasket thickness (Unit mm (in))
SELECTION OF DRIVEN PLATE No. 3
1. Install the drive plate and driven plate to center differential carrier.
2. Measure the depth A from the mating surface of extension case to multi-plate clutch (LSD) piston.
3. Using the ST, measure the height B from the intermediate case mating surface to end of ST, and then subtract the thickness of ST (piston guide) (50 mm (1.97 inch)) from measured value.
ST 398744300 PISTON GUIDE
4. Calculation formula:
When clearances are 0.2 mm (0.008 inch):
T (mm) = A - B + 0.08
[T (in) = A- B + 0.0031]
When clearances are 0.6 mm (0.024 inch):
T (mm) = A - B + 0.32
[T (in) = A - B + 0.0126]
T: Thickness of driven plate No. 3
A: Depth from mating surface of extension case to multi-plate clutch (LSD) piston
B: Height from mating surface of intermediate case to end surface of ST
Specification: 0.2-0.6 mm (0.008-0.024 inch)
NOTE: Calculation formula for "T" applied when measuring using ST (398643600 GAUGE, 398744300 PISTON GUIDE). When not using ST, apply following.
When clearances are 0.2 mm (0.008 inch):
T (mm) = A - (B - a - 0.28) - 0.2
[T (in) = A - (B - a - 0.011) - 0.008]
When clearances are 0.6 mm (0.024 inch):
T (mm) = A - (B - a - 0.28) - 0.6
[T (in) = A - (B - a - 0.011) - 0.024]
T: Thickness of driven plate No. 3
A: Depth from mating surface of extension case to multi-plate clutch (LSD) piston
B: Height from mating surface of intermediate case to end surface of tool as substitution for ST a: Tool thickness used when measuring B 0.28 (0.011): Gasket thickness (Unit mm (in))
If out of specification, select the driven plate No. 3 to adjust within the specification.