Disassembly

DISASSEMBLY OF TRANSFER








1. REMOVE DIAPHRAGM CYLINDER (ELECTRICAL SHIFT TYPE) (See Diaphragm Cylinder)




2. REMOVE TRANSFER FRONT DRIVE SHIFT LEVER (MECHANICAL SHIFT TYPE)
(a) Remove the transfer front drive shift lever.
(b) Remove the dust boot.




3. REMOVE 4WD INDICATOR SWITCH
Using SST, remove the 4WD indicator switch. SST 09817-16011




4. REMOVE L4 POSITION SWITCH (ELECTRICAL SHIFT TYPE)




5. REMOVE PLUGS, SPRINGS AND LOCKING BALLS
[Mechanical Shift Type]
Remove the plugs and, using a magnetic finger, remove the springs and locking balls.
[Electrical Shift Type]
Remove the plug and, using a magnetic finger, remove the spring and locking ball.




6. REMOVE SPEEDOMETER DRIVEN GEAR




7. REMOVE TRANSMISSION OUTPUT SHAFT LOCK NUT
(a) Remove the transfer case cover No.2 and gasket.
(b) Using a hammer and chisel, loosen the staked part of the nut.




(c) Using SST to hold the rear companion flange, remove the transmission output shaft lock nut. SST 09330-00021




8. REMOVE FRONT AND REAR COMPANION FLANGE
(a) Using a hammer and chisel, loosen the staked part of the nut.
(b) Using SST to hold the companion flange, remove the companion flange lock nut. SST 09330-00021
(c) Remove the companion flange.




9. REMOVE POWER TAKE-OFF COVER
Remove the six bolts, and remove the power take-off cover.




10. MEASURE IDLER GEAR THRUST CLEARANCE
Using a feeler gauge, measure the clearance between the idler gear and thrust washer.
Standard clearance : 0.275 - 0.625 mm (0.0110 - 0.0246 in.)
Maximum clearance : 0.625 mm (0.0246 in.)




11. REMOVE REAR OUTPUT SHAFT REAR BEARING RETAINER
(a) Remove the six bolts, and remove the rear output shaft rear bearing retainer.




(b) Remove the speedometer drive gear and spacer.




12. REMOVE IDLER GEAR SHAFT LOCK PLATE




13. REMOVE TRANSFER REAR CASE
(a) Remove the bolts.
(b) Using a plastic hammer, remove the transfer rear case.




14. REMOVE REAR OUTPUT SHAFT ASSEMBLY WITH SHIFT FORK AND SHIFT FORK SHAFT




15. REMOVE SHIFT FORK SHAFT
(a) Using a pin punch and hammer, drive out the slotted spring pin.
(b) Remove the shift fork shaft from the shift fork.

NOTE: Use a set of soft jaws in the vise to protect the shift fork.




16. REMOVE TRANSFER INPUT GEAR BEARING, POWER TAKE-OFF DRIVE GEAR AND SPACER
(a) Using SST, remove the transfer input gear bearing. SST 09950-20016
(b) Remove the power take-off drive gear and spacer.




17. REMOVE TRANSFER INPUT GEAR
Using SST, remove the transfer input gear. SST 09950-20016
18. REMOVE 0-RING FROM TRANSMISSION OUTPUT SHAFT (ATM)




19. REMOVE IDLER GEAR, BEARINGS, SPACER THRUST WASHERS AND IDLER GEAR SHAFT
(a) Remove the 0-ring.
(b) Remove the idler gear, thrust washers, bearing and spacer.
(c) Remove the idler gear shaft.




20. REMOVE REAR OUTPUT SHAFT FRONT BEARING RETAINER
Using SST, remove the output shaft front bearing retainer. SST 09308-10010




21. REMOVE CLUTCH SLEEVE
Remove the clutch sleeve with the shift fork and shift fork shaft.




22. REMOVE SHIFT FORK SHAFT
[Mechanical Shift Type]
(a) Using a pin punch and hammer, drive out the slotted spring pin.
(b) Remove the shift fork from the shift fork shaft.




[Electrical Shift Type]
(a) Remove the retainer, spring and shift fork from the shift fork shaft.




(b) Using snap ring pliers, remove the snap ring.




23. REMOVE TRANSFER FRONT CASE
(a) Remove the four bolts (5-Speed) or five bolts (4-Speed).
(b) Using a plastic hammer, remove the transfer front case.
(c) Remove the adjusting shim from the transfer front case. (ATM)




24. REMOVE FRONT OUTPUT SHAFT
Using a press, remove the front output shaft.




25. REMOVE TRANSFER HIGH AND LOW SHIFT OUTER AND INNER LEVER




26. MEASURE THRUST CLEARANCE OF HIGH AND LOW GEAR
(a) Using a feeler gauge, measure the thrust clearance of the high gear.
Standard clearance: MTM 0.10-0.25 mm (0.0039 - 0.0098 in.)
ATM 0.15-0.30 mm (0.0059 - 0.0118 in.)
Maximum clearance: MTM 0.25 mm (0.0098 in.)
ATM 0.30 mm (0.0118 in.)




(b) Using a feeler gauge, measure the thrust clearance of the low gear.
Standard clearance: MTM 0.10-0.25 mm (0.0039 - 0.0098 in.)
ATM 0.15-0.30 mm (0.0059 - 0.0118 in.)
Maximum clearance: MTM 0.25 mm (0.0098 in.)
ATM 0.30 mm (0.0118 in.)




27. REMOVE HIGH GEAR FROM REAR OUTPUT SHAFT
(a) Using snap ring pliers, remove the snap ring.




(b) Using a press and socket wrench, remove the following parts.
- Clutch hub
- Output shaft front bearing
- High gear
- High gear bearing (ATM)
- Clutch sleeve




28. REMOVE LOW GEAR FROM REAR OUTPUT SHAFT
Using a press, remove the following parts:
- Output shaft rear bearing
- Lowgear
- Low gear bearing (ATM)