Transfer Disassembly and Assembly
Transfer Disassembly and AssemblyDisassembly
Transfer assembly
NOTE: It is possible to disassemble transfer assembly without removing intermediate shaft with Step 1 to 4 performed if not necessary.
1. Remove intermediate output oil seal (1) from transfer right case (5).
2. Remove snap ring (2) by using special tool.
Special Tool: 09952-76011
3. Remove intermediate shaft (4) with intermediate shaft bearing (3).
4. Remove intermediate shaft bearing (3) from intermediate shaft (4) by using bearing puller and press.
5. Remove transfer output retainer assembly (1) and shims (3) by removing 4 bolts (2).
6. Remove 9 transfer case bolts (4).
7. Separate transfer right case (5) from transfer left case (6) by using special tool.
Special Tool (A): 09912-34510
8. Remove reduction drive gear assembly (7), reduction idler gear assembly (8) and reduction driven gear assembly (9).
9. Remove reduction idler gear taper roller bearing outer race (10), shim (11) and reduction driven gear RH taper roller bearing outer race (12) from transfer right case (5).
10. Remove reduction idler gear taper roller bearing outer race (10), reduction driven gear LH taper roller bearing outer race (13) from transfer left case (6).
NOTE: When it is difficult to remove taper roller bearing outer races from cases, remove them with special tool.
Special Tool (B): 09941-54911
Reduction drive gear, reduction idler gear and reduction driven gear
1. Drive out bearings of reduction drive gear, reduction idler gear and reduction driven gear by using bearing puller (1) and hydraulic press (2).
Transfer right case and left case
1. Remove oil seals (1) from transfer right case and left case by using special tool.
Special Tool (A): 09913-50121
2. Remove oil protect plate (2) and oil receiver (3) from transfer right case.
3. Remove adjuster plates (1) from transfer right and left cases.
4. Remove bevel gear adjuster (2) from transfer right and left case by using special tool.
Special Tool (A): 09940-14940
Transfer output retainer assembly
1. Uncaulk transfer output flange nut.
2. Remove transfer output flange nut while holding flange (1) by using special tool.
Special Tool (A): 09930-40113
3. Remove transfer output flange (1) by bearing puller (2).
4. Drive out bevel pinion shaft (1) from transfer output retainer by tapping it with plastic hammer (2).
5. Drive out pinion shaft bearing from bevel pinion shaft by using bearing puller and hydraulic press.
6. Remove pinion shaft oil seal (1) by using special tool.
Special Tool (A): 09913-50121
7. Remove pinion shaft RR taper roller bearing (1) and spacer (2).
8. Drive out pinion shaft taper roller bearing outer races (2) (front and rear) by using brass bar (1).
Assembly
Judging from faulty conditions noted before disassembly and what is found through visual check of bearing and gear tooth etc. after disassembly, prepare replacing parts and proceed to reassembly according to procedures as described in the following.
CAUTION:
^ Bevel gear and pinion must be replaced as a set when either replacement becomes necessary.
^ When replacing taper roller bearing, replace as inner race & outer race assembly.
Reduction drive gear, reduction idler gear and reduction driven gear
1. Drive in reduction drive gear bearings (right and left) to reduction drive gear by using bearing puller and hydraulic press.
2. Drive in reduction idler gear bearings (1) (right and left) to reduction idler gear (2) by using special tools and hydraulic press (5).
3. Drive in reduction driven gear bearings (3) (right and left) to reduction driven gear (4) by using special tools and hydraulic press (5).
Special Tool
(A): 09944-66060
(B): 09925-88210
Reduction gear taper roller bearings dimension
Reduction idler gear taper roller bearing 47 mm (1.85 inch) 15 mm (0.59 inch)
Reduction driven gear RH taper roller bearing 52 mm (2.05 inch) 16.3 mm (0.64 inch)
Reduction driven gear LH taper roller bearing 52 mm (2.05 inch) 19.3 mm (0.76 inch)
Transfer output retainer assembly
To mesh bevel gears correctly, it is prerequired to install bevel pinion to transfer output retainer properly by using adjusting shim (bevel pinion shim) as described on following steps.
1. Press-fit pinion shaft taper roller bearing outer races (front and rear) by using special tools and hydraulic press (1).
Special Tool
(A): 09913-75821
(B): 09924-84510-002
(C): 09924-84510-005
(D): 09951-18210
2. Press-fit pinion shaft FR taper roller bearing by using special tools and hydraulic press.
Special Tool
(A): 09941-74910
(B): 09925-88210
3. Install bevel pinion shaft with new pinion shaft spacer to transfer output retainer.
4. Drive in pinion shaft RR taper roller bearing by using special tool and tapping lightly with plastic hammer (1).
Special Tool (A): 09913-75810
5. Apply grease to new oil seal lip.
"A": Grease 99000-25010
6. Drive in oil seal (1) by using special tool and hammer.
Special Tool (A): 09913-75810
Transfer output flange oil seal installing depth "a": 1.0 - 2.0 mm (0.04 - 0.08 inch)
7. Install transfer output flange (1) by tapping with plastic hammer and tighten transfer output flange nut gradually so as rotational torque of bevel pinion shaft to be in specified value.
NOTE:
^ If rotational torque of bevel pinion shaft exceeds specification given in the following, replace pinion shaft spacer and tighten flange nut.
^ Before taking measurement of rotational torque, rotate pinion shaft over ten rounds in advance.
Special Tool (A): 09930-40113
Tightening torque
Transfer output flange nut (reference) 90 - 150 Nm (9.0 - 15.0 kgf-cm, 65.0 - 108 ft. lbs.)
Rotational torque of bevel pinion shaft (Bearing preload) 0.5 - 1.50 Nm (5.0 - 15.0 kgf-cm, 0.35 - 1.10 ft. lbs.)
8. Caulk transfer output flange nut (1).
Transfer right case
1. Apply grease to reduction drive gear oil seal lips.
"A": Grease 99000-25010
2. Install reduction drive gear oil seals (1, 2) to right case (3) by using special tool.
CAUTION: Use care the installation direction and depth of oil seals for correct installation.
Special Tool: 09913-75520
Transfer reduction drive gear oil seal installing depth
"a": 13.3 - 14.3 mm (0.524 - 0.563 inch)
"b": 2.8 - 3.8 mm (0.110 - 0.150 inch)
3. Fill inside of oil seal (2) with grease of about 3 g (0.11 oz).
"B": Grease 99000-25010
4. Screw bevel gear adjuster (1) in right case (2) until side face of bevel gear adjuster (1) come to flush position with side face of right case (2) by using special tool.
Special Tool (A): 09940-14940
NOTE: Do not screw in bevel gear adjuster excessively, or preload of reduction idler gear taper roller bearing may not be adjusted accurately.
5. Install oil protect plate (1) and oil receiver (2) to right case (3).
Tightening torque
Oil protect plate bolts (a): 12 Nm (1.2 kgf-cm, 9.0 ft. lbs.)
Oil receiver bolt (b): 12 Nm (1.2 kgf-cm, 9.0 ft. lbs.)
Transfer left case
1. Apply grease to reduction drive gear oil seal lips.
"A": Grease 99000-25010
2. Install reduction drive gear oil seals (1) to left case (2) by using special tool.
CAUTION: Use care the installation direction and depth of oil seals for correct installation.
Special Tool: 09913-85210
Transfer reduction drive gear oil seal installing depth
"a": 13.0 - 14.0 mm (0.512 - 0.551 inch)
"b": 2.5 - 3.5 mm (0.098 - 0.138 inch)
3. Screw bevel gear adjuster (1) in left case (2) until side face of bevel gear adjuster (1) come to flush position with side face of left case (2) by using special tool.
Special Tool (A): 09940-14940
NOTE: Do not screw in bevel gear adjuster excessively, or preload of reduction idler gear taper roller bearing may not be adjusted accurately.
Reduction idler gear shim adjustment
1. Measure distance "a" between taper roller bearing outer races of reduction idler gear (1).
2. Measure depth "b" of left case (2) and "c" of right case (3).
3. Obtain adjusting shim thickness by the following equation.
Necessary shim thickness = Depth "b" + Depth "c" - Distance "a" + 0.05 mm (0.002 inch)
4. Select adjusting shim closest to calculated value from among the following available sizes.
Available reduction idler gear shim thickness
0.55, 0.60, 0.65, 0.70, 0.75, 0.80, 0.85, 0.90, 0.95, 1.00, 1.05, 1.10 and 1.15 mm (0.022, 0.024, 0.026, 0.028, 0.030, 0.031, 0.033, 0.035, 0.037, 0.039, 0.041, 0.043 and 0.045 inch)
Transfer assembly
1. Clean mating surface of right and left cases, and apply sealant to right case (1) by using a nozzle (2) as shown in figure by such amount that its section is 1.2 mm (0.047 inch) in diameter.
"A": Sealant 99000-31110
2. Assemble the following parts in right and left cases by reversing disassembling procedure.
^ Reduction drive gear assembly (1)
^ Reduction idler gear assembly (2)
^ Reduction driven gear assembly (3)
^ Reduction idler gear taper roller bearing outer races (4)
^ Reduction driven gear RH taper roller bearing outer race (5)
^ Reduction driven gear LH taper roller bearing outer race (6)
^ Reduction idler gear shim (7) . Knock pin (8)
3. Tighten 9 transfer case bolts (9) to specified torque.
Tightening torque
Transfer case bolts (a): 23 Nm (2.3 kgf-cm, 17.0 ft. lbs.)
Reduction idler gear taper roller bearing preload adjustment
1. Measure reduction drive gear staring toque (i.e., preload of reduction idler gear taper roller bearings) by using special tool and torque wrench (1).
Special Tool (A): 09928-36010
Starting torque of reduction drive gear (reduction idler gear bearing preload) 0.5 - 1.4 Nm (5 - 14 kg-cm, 0.35 - 1.0 ft. lbs.)
2. If starting torque is out of specification, replace reduction idler gear shim and measure staring torque again.
NOTE: Make a record of starting torque of reduction drive gear because it is used for adjusting reduction driven gear taper roller bearing preload.
Bevel gear back lash inspection
1. Install transfer output retainer assembly (1) with bevel pinion shims (2) selected in Transfer Bevel Pinion Shim Adjustment to transfer sub-assembly (3).
Tightening torque
Transfer output retainer bolts (a): 50 Nm (5.0 kgf-cm, 36.5 ft. lbs.)
2. Set torque wrench (1) on transfer output flange nut.
3. Screw bevel gear adjuster (2) on right case until transfer output flange (3) does not rotate by rotational torque with 10 - 20 Nm (100 - 200 kgf-cm, 7.5 - 14.5 ft. lbs.) by using special tool.
4. Loosen bevel gear adjuster (2) on right case to angle with 24 - 36° to make backlash between bevel gears.
Special Tool (A): 09940-14940
Bevel gear backlash 0.1 - 0.15 mm (0.004 - 0.006 inch)
5. Remove transfer output retainer assembly and bevel gear shims to measure reduction driven gear taper roller bearing preload.
Reduction driven gear taper roller bearing preload inspection
1. Screw bevel gear adjuster (1) on right case by using special tool while measuring starting torque of reduction drive gear (i.e., preload of reduction idler gear and driven gear taper roller bearings) by using special tool and torque wrench (2) until corrected starting torque value of reduction drive gear is in specified value shown as follows.
Special Tool
(A): 09928-36010
(B): 09940-14940
2. Correct starting torque to starting torque caused by only preload of reduction driven gear taper roller bearings by the following equation.
Tightening torque
Corrected starting torque of reduction drive gear (reduction driven gear bearing preload) 0.35 - 2.5 Nm (3.5 - 25 kgf-cm, 0.25 - 1.8 ft. lbs.)
Adjuster plate
1. Apply thread lock cement to thread part of adjuster plate bolts (1).
"A": Thread lock cement 99000-32110
2. Install adjuster plates (2) to transfer right and left case so as one side of plate claw to touch dent wall of bevel gear adjuster (3) as shown in figure to prevent bevel gear adjusters (3) from loosing.
Tightening torque
Adjuster plate bolts (a): 12 Nm (1.2 kgf-cm, 9.0 ft. lbs.)
Bevel gear tooth contact inspection
1. After cleaning tooth surface of bevel gear (1), paint them with gear marking compound evenly by using brush or sponge etc.
NOTE: When applying red lead paste to teeth, be sure to paint tooth surfaces uniformly. The paste must not be too dry or too fluid.
2. Install transfer output retainer assembly with bevel pinion shims selected in Transfer Bevel Pinion Shim Adjustment to transfer sub-assembly.
Tightening torque
Transfer output retainer bolts 50 Nm (5.0 kgf-cm, 36.5 ft. lbs.)
3. Turn transfer output flange clockwise and counterclockwise repeatedly, and remove transfer output retainer assembly and bevel gear shims from transfer sub-assembly.
4. Bring painted part up and check contact pattern, referring to following chart. If contact pattern is not normal, readjust or replace as necessary.
NOTE:
^ Be careful not to turn bevel gear more than one full revolution, for it will hinder accurate check.
^ If bevel gear back lash and bevel pinion shims are adjusted properly, correct tooth contact should be provided. If correct tooth contact is not provided even when they are adjusted properly, however, there may be an abnormal condition in worn tooth, transfer case or retainer. Check each component and replace as necessary.
Gear tooth contact table
Transfer output retainer assembly
1. Apply sealant to one of retainer bolts (1).
"A": Sealant 99000-31110
2. Install transfer output retainer assembly (2) with bevel pinion shims (3) selected in Transfer Bevel Pinion Shim Adjustment to transfer sub-assembly (4) by tightening retainer bolts (1) to specified torque.
Tightening torque
Transfer output retainer bolts (a): 50 Nm (5.0 kgf-cm, 36.5 ft. lbs.)
Intermediate shaft and oil seal
1. Install intermediate shaft bearing (2) to intermediate shaft (3) by using special tool.
Special Tool: 09941-74910
2. Install intermediate shaft with bearing in transfer (4).
3. Install snap ring (1) to transfer right case by using special tool.
Special Tool : 09952-76011
4. Apply grease to new intermediate output oil seal lip.
"A": Grease 99000-25010
5. Drive intermediate output oil seal (1) in transfer right case (2) by using special tool and hammer.
Special Tool (A): 09925-15410
Intermediate output oil seal installing depth "a": 1.0 - 2.0 mm (0.04 - 0.08 inch)