Transfer Clutch

Transfer Clutch

REMOVAL
1. Remove the transmission assembly from vehicle.
2. Remove the extension case, and then remove the transfer clutch.

INSTALLATION
1. Select the thrust needle bearing.





2. Install the transfer clutch assembly to the case.





3. Tighten the bolts to secure the case.
Tightening torque: 25 Nm (2.5 kgf-cm, 18 ft. lbs.)
4. Install the transmission assembly into vehicle.

DISASSEMBLY





1. Remove the seal ring.





2. Remove the ball bearing using ST and press.
ST 498077600 REMOVER





3. Remove the snap ring, and then take out the pressure plate, drive plate and driven plate.





4. Using the ST1, ST2 and ST3, remove the snap ring, and then take out the return spring and transfer clutch piston seal.
ST1 399893600 PLIERS
ST2 398673600 COMPRESSOR
ST3 398623600 SEAT





5. Apply compressed air to the rear drive shaft to remove transfer clutch piston.

ASSEMBLY





1. Install the transfer clutch piston.





2. Install the return spring to transfer clutch piston.





3. Apply ATF, to the lip of transfer clutch piston seal and install it.





4. Install the ST to the rear drive shaft.
ST 499257300 SNAP NAP RING OUTER GUIDE





5. Install the snap ring to ST.
ST 499257300 SNAP RING OUTER GUIDE





6. Install the snap ring to rear drive shaft using ST1 and ST2.
ST1 499257300 SNAP RING OUTER GUIDE
ST2 499247400 INSTALLER





7. Install the driven plate, drive plate, pressure plate and snap ring.





8. Apply compressed air to see if the assembled parts move smoothly.
9. Check clearance between snap ring and pressure plate.





10. Press-fit new ball bearing using ST.
ST 899580100 INSTALLER





11. Apply Vaseline to a new seal ring and attach to the seal ring groove of the shaft.

NOTE: While installing the seal ring, not to expand the seal ring excessively.





12. Install the transfer clutch assembly without damaging seal ring.

INSPECTION
^ Inspect the drive plate facing for wear and damage.
^ Inspect the snap ring for wear, return spring for permanent distortion, breakage and deformation.
^ Inspect the D-ring for damage.
^ Inspect the extension end play and adjust it to within specifications.

1. Check clearance between snap ring and pressure gauge.
2. Before measuring clearance, place the same thickness of shim on both sides to prevent pressure plate from tilting.





3. If the clearance is not within specification, adjust it by selecting a suitable pressure plate on transfer clutch piston side.
Initial standard: 0.7 - 1.1 mm (0.028 - 0.043 inch)
Limit thickness: 1.6 mm (0.063 inch)
4. Check that the tight corner braking does not occur when the vehicle is started with steering wheel held at fully turned position. If tight corner braking occurs, perform the following procedures.
1. With the steering wheel held at fully turned position, drive the vehicle in D range and with vehicle speed at approximately 5 km/h (3 MPH) in both clockwise and counterclockwise directions for approximately ten times each, while repeating acceleration and braking intermittently.
2. If the tight corner braking still persists, drive the vehicle again in a circle for several laps.

ADJUSTMENT





1. Measure the distance A from the end surface of ST to rear drive shaft using ST.
ST 398643600 GAUGE





2. Measure the distance B from the transmission case mating surface to the ST end surface using ST1 and ST2.
ST1 398643600 GAUGE
ST2 499577000 GAUGE





3. Calculation formula:
NOTE:
Calculate T:
T = A - B + 35.4 mm
[T = A - B + 1.3937 inch]
T: Thrust needle bearing thickness
A: Distance from the end surface of ST to the end of rear drive shaft
B: Distance from the mating surface of transmission case to the end surface of ST
Example:
When, A = 33.6 mm (1.3228 inch), B = 65.05 mm (2.5610 inch)
T = 33.6 - 65.05 + 35.4 = 3.95
[T = 1.3228 - 2.5610 + 1.3937 = 0.1555]
After calculation, the value of T becomes 3.95, therefore select bearing thickness of 3.8 mm (0.150 inch).

NOTE: Calculation formula for T is applied when measuring using ST (398643600 GAUGE, 499577000 GAUGE). When not using ST, apply
T=(A-a+0.45mm)-(B-)-H
[T=(A-a+0.0177in)-(B-)-H]
T: Thrust needle bearing thickness
A: Distance from end surface of collar as substitute for ST to end of reduction drive shaft
B: Distance from mating surface of transmission case to end surface of collar as substitute for ST
a: Collar thickness used when measuring "A"
b: Collar thickness used when measuring "B"
0.45: Gasket thickness (mm)
0.0177: Gasket thickness (in)
H: Shim clearance