W/O One-Touch

NOTE: For removal and installation procedures refer to "Transfer Case, Service and Repair."





DISASSEMBLY





1. Inspect drive sprocket thrust clearance.
Using a feeler gauge, measure the drive sprocket thrust clearance.
Standard clearance: 0.10 - 0.25 mm (0.0039 - 0.0098 inch)
Maximum clearance: 0.25 mm (0.0098 inch)
If the clearance exceeds the maximum, replace the drive sprocket.





2. Remove high and low clutch sleeve assembly.
a. Using a snap ring expander, remove the snap ring.
b. Remove the clutch sleeve.
c. Using a press, remove the clutch hub.
3. Remove bearing, spacer and drive sprocket with front drive clutch sleeve assembly





a. Using Special Service Tool (SST) 09555 - 55010 and a press, remove the bearing.





b. Remove these parts.
- Spacer and ball
- Drive sprocket with front drive clutch sleeve assembly
- Needle roller bearing
- Synchronizer ring
4. Remove shifting keys and key springs from front drive clutch sleeve.

INSPECTION





1. Inspect rear output shaft.
Using a micrometer, measure the outer diameter of the rear output shaft journal surface.
Minimum diameter:
Part A: 27.98 mm (1.1016 inch)
Part B: 36.98 mm (1.4561 inch)





2. Inspect drive sprocket radial clearance.
Using a dial indicator, measure the radial clearance between the sprocket and shaft with the needle roller bearing installed.
Standard clearance: 0.010 - 0.055 mm (0.0004 - 0.0022 inch)
Maximum clearance: 0.055 mm (0.0022 inch)
If the clearance exceeds the maximum, replace the drive sprocket, rear output shaft or needle roller bearing.





3. Inspect front drive shift fork and clutch sleeve clearance.
Using a feeler gauge, measure the clearance between the front drive shift fork and clutch sleeve.
Maximum clearance: 1.0 mm (0.039 inch)
If the clearance exceeds the maximum, replace the shift fork or clutch sleeve.





4. Inspect high and low shift fork and clutch sleeve clearance.
Using a feeler gauge, measure the clearance between the high and low shift fork and clutch sleeve.
Maximum clearance: 1.0 mm (0.039 inch)
If the clearance exceeds the maximum, replace the shift fork or clutch sleeve.

REASSEMBLY
1. Install front drive clutch sleeve onto drive sprocket.





a. Install the front drive clutch sleeve onto the drive sprocket.

HINT: Make sure to install the clutch sleeve in the correct direction.





b. Install the shifting keys and springs.

NOTICE: Install the key springs positioned so that their end gaps are not in line.

2. Install drive sprocket with front drive clutch sleeve assembly, spacer and bearing.





a. Apply gear oil to the shaft and needle roller bearing.
b. Place the synchronizer ring on the spline and align the ring slots with the shifting keys.
c. Install the needle roller bearing in the drive sprocket.
d. Install the drive sprocket with the front drive clutch sleeve assembly.





3. Inspect drive sprocket thrust clearance.
Using a feeler gauge, measure the drive sprocket thrust clearance.
Standard clearance: 0.10 - 0.25 mm (0.0039 - 0.0098 inch)





4. Insert high and low clutch hub onto clutch sleeve.
Install the clutch hub onto the clutch sleeve.





5. Install high and low clutch hub assembly.
Using a press, install the high and low clutch hub assembly.





6. Install snap ring.





Select a snap ring that will allow minimum axial play and install it to the shaft.