Transfer Clutch

Transfer Clutch

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

INSTALLATION
1) Select the thrust needle bearing.
2) Install the transfer clutch assembly to the case.





3) Replace with new gasket, and tighten bolts to secure the case.





4) Install the transmission assembly to vehicle.

DISASSEMBLY
1) Remove the seal ring.





2) Using a press and ST, remove the ball bearing.
ST 498077600 REMOVER





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





4) Remove the snap ring with ST1, ST2 and ST3, and 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 the piston.





ASSEMBLY
1) Install the transfer clutch piston.





2) Install return spring to transfer piston.





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





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





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





6) Using ST1 and ST2, install snap ring to rear drive shaft.
ST1 499257300 SNAP RING OUTER GUIDE
ST2 499247400 INSTALLER





7) Install the driven plates, drive plates, 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 a new ball bearing with ST.
ST 899580100 INSTALLER





11) Coat a new seal ring with Vaseline, and install it in the seal ring groove of the shaft.

NOTE:
Do not expand the seal ring excessively when installing.





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





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

1) Inspect clearance between snap ring and pressure plate.
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 the transfer clutch piston side. If it exceeds the service limit, replace the drive plate with new one and adjust it within the specification by selecting the pressure plate.








4) Check if 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

MP-T MODEL
1) Using the ST, measure the distance "A" from the end surface of ST to the end surface of rear drive shaft.
ST 398643600 GAUGE





2) Using the ST1 and ST2, measure the distance "B" from the transmission case mating surface to the end surface of ST.
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 surface 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 (2.5 610 inch)
T = 33.6 - 65.05 + 35.4 = 3.95
[T = 1. 3228 - 2.5610 + 1.3937 = 0. 1555]
After calculation, the valve of "T" becomes 3.95 mm (0.1555 inch), 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 + 0.45 mm) - (B - P) - H
[T (A - a + 0.0177 inch) - (B - P) - H].

T: Thrust needle bearing thickness
A: Distance from the end surface of collar as substitute for ST to the end surface of reduction drive shaft
B: Distance from the mating surface of transmission case to the end surface of collar as substitute for ST
a: Collar thickness used when measuring "A"
P: Collar thickness used when measuring "B"
0.45 (0.0177): Gasket thickness (mm (in))
H: Shim clearance





VTD MODEL
1) Insert the rear driveshaft into the reduction drive gear and center differential assembly.





2) Using the ST, measure the distance "A" from the end surface of ST to the ball bearing outer ring contact surface of rear drive shaft.
ST 398643600 GAUGE





3) Using the ST, measure the distance "B" from the mating surface of transmission case to the end surface of ST.
ST 398643600 GAUGE





4) Formula:

NOTE:
Calculation of "T":
When clearances are 0.05 mm (0.0020 inch), select up to four adjusting shims from the table, suitable for clearance value.
When clearances are 0.05 mm (0.0020 inch)
T - A - B + 0.40 mm
[T = A - B + 0.0157 inch]
When clearances are 0.25 mm (0.0098 inch)
T = A - B + 0.20 mm
[T = A - B + 0.0079 inch]
T: Shim clearance
A: Distance from the end surface of ST to the ball bearing outer ring contact surface of rear drive shaft
B: Distance from the mating surface of transmission case to the end surface of ST
T: Shim thickness
0.05 - 0.25 mm (0.0020 - 0.0098 inch)
Example:
When, A = 90.50 mm (3.5630 inch), B = 90.35 mm (3.5571 inch)
Calculation for 0.05 mm (0.0020 inch) of clearance
T 90.50 - 90.35 + 0.4 = 0.55
[T = 3.5630 - 3.5571 + 0.0157 = 0.0216]
Calculation when clearance is 0.25 mm (0.0098 inch)
T 90.50 - 90.35 + 0.2 = 0.35
[T = 3.5630 - 3.5571 + 0.0079 = 0.0138]

NOTE:
Calculation formula for "T" is applied when measuring using ST (398643600 GAUGE). When not using ST, apply
T = (A - a + 0.45 mm) - (B - H
[T = (A - a + 0.0177 inch) - (B - - H]
T: Thrust needle bearing thickness
A: Distance from the end surface of collar as substitute for ST to the rear drive shaft ball bearing outer ring contact surface
B: Distance from the mating surface of transmission case to the end surface of collar as substitute for ST
a: Collar thickness used when measuring "A"
P: Collar thickness used when measuring "B"
0.45 (0.0177): Gasket thickness (mm (in))
H: Shim clearance After calculation, the value of "T" becomes between 0.35 mm (0.0138 inch) and 0.55 mm (0.0216 inch), therefore select two shims with thickness of 0.2 mm (0.010 inch) or one shim with thickness of 0.5 mm (0.020 inch).