Transfer Assembly

DISASSEMBLY
1. REMOVE VEHICLE SPEED SENSOR ASSEMBLY
a) Remove the bolt and vehicle speed sensor assembly.
b) Using a small screwdriver, remove the clip and vehicle speed sensor driven gear.
c) Using a small screwdriver, remove the O-ring.

HINT: Tape the small screwdriver tip before use.

2. REMOVE L4 POSITION SWITCH, NEUTRAL POSITION SWITCH AND CENTER DIFFERENTIAL LOCK INDICATOR SWITCH WITH 3 GASKETS





3. REMOVE CASE COVER
Remove the 5 bolts and case cover.

HINT: If necessary, tap the case cover with a plastic hammer to remove it.

4. REMOVE CONTROL SHIFT LEVER RETAINER
a) Remove the 4 bolts, control shift lever retainer and oil deflector.
b) Remove the select return spring from the control shift lever retainer.
5. REMOVE FRONT COMPANION FLANGE
a) Using a chisel and hammer, loosen the staked part of the front companion flange lock nut.





b) Using SST to hold the front companion flange, remove the front companion flange lock nut.
SST 09330-00021





c) Using SST, remove the front companion flange.
SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04051, 09957-04010, 09950-04011)
6. REMOVE REAR COMPANION FLANGE
Remove the rear companion flange in the same way as the front companion flange.





7. REMOVE EXTENSION HOUSING
Remove the 5 bolts and extension housing.

HINT: If necessary, tap the extension housing with a plastic hammer to remove it.

8. REMOVE VEHICLE SPEED SENSOR DRIVE GEAR AND OUTPUT SHAFT WASHER
a) Remove the vehicle speed sensor drive gear and 2 output shaft washers.
b) Using a magnetic finger, remove the ball from the rear output shaft.





9. REMOVE REAR CASE
Remove the 12 bolts, 2 clamps and rear case.

HINT: If necessary, tap the rear case with a plastic hammer to remove it.





10. REMOVE STRAIGHT SCREW PLUG, SPRING AND BALL
a) Using a hexagon wrench, remove the 2 straight screw plugs.
b) Using a magnetic finger, remove the 2 springs and balls.
11. REMOVE SHIFT STOPPER, NO.2 GEAR SHIFT FORK, FRONT DRIVE SHIFT FORK SHAFT AND HIGH AND LOW SHIFT FORK SHAFT





a) Using 2 screwdrivers and a hammer, tap out the 2 snap rings.





b) Using a pin punch and hammer, tap out the 2 slotted spring pins from the shift stopper and No. 2 gear shift fork.





c) Remove the shift stopper, No. 2 gear shift fork, front drive shift fork shaft, high and low shift fork shaft and shift interlock pin.
12. REMOVE GEAR SHIFT FORK SHAFT





a) Using 2 screwdrivers and a hammer, remove the 3 snap rings from the gear shift fork shaft.





b) Using a hexagon wrench, remove the 2 straight screw plugs, springs and balls from the No.1 gear shift fork and center differential lock fork.





c) Remove the bolt and shift shaft stopper.





d) Rotate the slit portion of the gear shift fork shaft to the No. 2 shift interlock pin and remove it.





e) Using a magnetic finger, remove the 2 No. 2 shift interlock pins from the No.1 gear shift fork and center differential lock fork.
13. REMOVE REAR OUTPUT SHAFT ASSEMBLY, NO.1 GEAR SHIFT FORK, CENTER DIFFERENTIAL LOCK FORK, DRIVEN SPROCKET ASSEMBLY AND FRONT DRIVE CHAIN





a) Using 2 screwdrivers and a hammer, tap out the 2 snap rings from the gear shift fork shaft of the actuator assembly.
b) Using a snap ring expander, remove the output shaft snap ring.





c) Mount the rear case in a vise, as shown.
d) Using a plastic hammer, carefully tap the rear case, and remove the rear output shaft assembly, No.1 gear shift fork, center differential lock fork, driven sprocket assembly and front drive chain.





e) Remove the front driven chain, driven sprocket assembly, center differential lock fork and No.1 gear shift fork from the rear output shaft assembly.
14. REMOVE ACTUATOR ASSEMBLY
a) Remove the 3 bolts and actuator assembly.
b) Remove the O-ring, No.1 and No. 2 4WD position switches with the 2 gaskets from the actuator assembly.





15. REMOVE OIL SEPARATOR AND MAGNET
a) Remove the 3 bolts and oil separator.
b) Remove the magnet from the front case.
16. REMOVE OIL PUMP BODY ASSEMBLY
Remove the 3 bolts and oil pump body assembly.





17. REMOVE OIL PUMP GEAR FROM FRONT CASE





18. REMOVE LOW PLANETARY GEAR ASSEMBLY WITH INPUT SHAFT ASSEMBLY
a) Using a snap ring expander, remove the low planetary gear bearing snap ring.
b) Pull out the planetary gear assembly with the input shaft assembly.





19. REMOVE LOW PLANETARY GEAR SPLINE PIECE
a) Using a screwdriver, remove the low planetary gear snap ring.
b) Remove the low planetary gear spline piece.





20. REMOVE OUTPUT SHAFT NEEDLE ROLLER BEARING FROM INPUT SHAFT





21. REMOVE INPUT GEAR STOPPER, LOW PLANETARY CARRIER THRUST WASHER AND INPUT GEAR STOPPER BALL
a) Using a snap ring expander, remove the input gear stopper snap ring.
b) Remove the input gear stopper, low planetary carrier thrust washer and input gear stopper ball.





22. REMOVE INPUT SHAFT ASSEMBLY, LOW PLANETARY GEAR BEARING AND NO.2 THRUST BEARING RACE
23. REMOVE LOW PLANETARY RING GEAR





a) Using a screwdriver, remove the low planetary ring gear hole snap ring.
b) Remove the head screw plug, spring and pin.





c) Remove the low planetary ring gear.








24. INSPECT SWITCH
Check that there is continuity between terminals, as shown.
If operation is not as specified, replace the switch.

REASSEMBLY

HINT: Coat all of the sliding and rotating surface with gear oil before reassembly.





1. INSTALL LOW PLANETARY RING GEAR
a) Install the low planetary ring gear.

NOTICE: Make sure to install the low planetary ring gear in the correct direction.

b) Install the spring and pin.
c) Apply sealant to the head screw plug threads.
Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
d) Install the head screw plug.
Torque: 19 Nm (190 kgf-cm, 14 ft. lbs.)





e) Using a screwdriver, install the low planetary ring gear hole snap ring.

NOTICE: Be sure the end gap of the snap ring is not aligned with the upper side of the case.

2. INSTALL NO.2 THRUST BEARING RACE, LOW PLANETARY GEAR BEARING AND INPUT SHAFT ASSEMBLY
3. INSTALL INPUT GEAR STOPPER BALL, LOW PLANETARY CARRIER THRUST WASHER AND INPUT GEAR STOPPER





a) Install the input gear stopper ball, low planetary carrier thrust washer and input gear stopper.








b) Select a input gear stopper snap ring that allows 0.05 - 0.15 mm (0.0020 - 0.0059 inch) axial play.
c) Using a snap ring expander, install a new input gear stopper snap ring.
4. INSTALL OUTPUT SHAFT NEEDLE ROLLER BEARING TO INPUT SHAFT





5. INSTALL LOW PLANETARY GEAR SPLINE PIECE
a) Install the low planetary gear spline piece.
b) Using a screwdriver, install the low planetary gear snap ring.

NOTICE: Be sure the end gap of the snap ring is not aligned with cutout portion of the low planetary gear.

6. INSTALL LOW PLANETARY GEAR ASSEMBLY WITH INPUT SHAFT ASSEMBLY
a) Install the low planetary gear assembly with the input shaft assembly.

HINT: If necessary, heat the front case to about 50 - 80°C (122 - 176°F).

b) Using a snap ring expander, install the low planetary gear bearing snap ring.

HINT: Check that the low planetary gear assembly and input shaft assembly turn lightly.

7. INSTALL OIL PUMP GEAR TO FRONT CASE
8. INSTALL OIL PUMP BODY ASSEMBLY
Install the oil pump body assembly with the 3 bolts.
Torque: 7.5 Nm (80 kgf-cm, 69 inch lbs.)
9. INSTALL MAGNET AND OIL SEPARATOR
a) Install the magnet to the front case.
b) Install the oil separator with the 3 bolts.
Torque: 7.5 Nm (80 kgf-cm, 69 inch lbs.)
10. INSTALL ACTUATOR ASSEMBLY
a) Install a new O-ring, No.1 and No. 2 4WD position switches with 2 new gaskets.
Torque: 37 Nm (380 kgf-cm, 27 ft. lbs.)
b) Install the actuator assembly with the 3 bolts.
Torque: 20 Nm (200 kgf-cm, 14 ft. lbs.)
11. INSTALL REAR OUTPUT SHAFT ASSEMBLY, NO.1 GEAR SHIFT FORK, CENTER DIFFERENTIAL LOCK FORK, DRIVEN SPROCKET ASSEMBLY AND FRONT DRIVE CHAIN





a) Install the No.1 gear shift fork, center differential lock fork, driven sprocket assembly and front drive chain to the rear output shaft assembly.

NOTICE: Make sure to install the forks in the correct direction.

b) Install the rear output shaft assembly with the driven sprocket assembly to the rear case.

NOTICE: Do not let the clutch sleeve and shifting key drop.

HINT: If necessary, heat the rear case to about 50 - 80°C (122 - 176°F).

c) Using a snap ring expander, install the output shaft snap ring.

HINT: Check that the rear output shaft assembly and driven sprocket turn lightly.





d) Using a screwdriver and hammer, drive in the 2 snap rings to the gear shift fork shaft of the actuator assembly.
12. INSTALL GEAR SHIFT FORK SHAFT





a) Using a magnetic finger, install the 2 No. 2 shift interlock pins to the No.1 gear shift fork and center differential lock fork.





b) Install the slit portion of the gear shift fork shaft with it facing No. 2 interlock pin and rotate the gear shift fork shaft, as shown in the illustration.





c) Install the shift shaft stopper with the bolt.
Torque: 19 Nm (190 kgf-cm, 14 ft. lbs.)





d) Install the 2 springs and balls to the No.1 gear shift fork and center differential lock fork.
e) Apply sealant to the straight screw plug threads.
Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
f) Using a hexagon wrench, install the 2 straight screw plugs to the No.1 gear shift fork and center differential lock fork.
Torque: 19 Nm (190 kgf-cm, 14 ft. lbs.)





g) Using a screwdriver and hammer, drive in the 3 snap rings to the gear shift fork shaft of the actuator assembly.
13. INSTALL HIGH AND LOW SHIFT FORK SHAFT, FRONT DRIVE SHIFT FORK SHAFT, NO. 2 GEAR SHIFT FORK AND SHIFT STOPPER





a) Install the shift interlock pin, high and low shift fork shaft, front drive shift fork shaft, No. 2 gear shift fork and shift stopper.

NOTICE: Make sure to install the No. 2 gear shift fork and shift stopper in the correct direction.





b) Using a pin punch and hammer, drive in the 2 slotted spring pins to the shift stopper and No. 2 gear shift fork.
14. INSTALL STRAIGHT SCREW PLUG, SPRING AND BALL





a) Install the 2 balls and springs.
b) Apply sealant to the straight screw plug threads.
Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
c) Using a hexagon wrench, install the 2 straight screw plugs.
Torque: 19 Nm (190 kgf-cm, 14 ft. lbs.)





d) Using a screwdriver and hammer, drive in the 2 snap rings.





15. INSTALL REAR CASE
a) Apply FIPG to the rear case, as shown.
FIPG:
Part No. 08826-00090, THREE BOND 1281 or equivalent
b) Install the rear case and 2 clamps with the 12 bolts.
Torque: 28 Nm (285 kgf-cm, 21 ft. lbs.)
16. INSTALL VEHICLE SPEED SENSOR DRIVE GEAR AND OUTPUT SHAFT WASHER
a) Install the ball on the rear output shaft.
b) Install the vehicle speed sensor drive gear and 2 output shaft washer.





17. INSTALL EXTENSION HOUSING
a) Apply FIPG to the extension housing, as shown.
FIPG:
Part No. 08826-00090, THREE BOND 1281 or equivalent
b) Apply sealant to the bolt threads.
Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
c) Install the extension housing with the 5 bolts.
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)





18. INSTALL FRONT COMPANION FLANGE
a) Install the front companion flange to the input shaft assembly.
b) Using SST to hold the front companion flange, install a new front companion flange lock nut.
SST 09330-00021
Torque: 118 Nm (1,200 kgf-cm, 87 ft. lbs.)
c) Stake the front companion flange lock nut.
19. INSTALL REAR COMPANION FLANGE
Install the rear companion flange in the same way as the front companion flange.
20. INSTALL CONTROL SHIFT LEVER RETAINER
a) Install the select return spring to the control shift lever retainer.
b) Install the control shift lever retainer and a new oil deflector with the 4 bolts.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)





21. INSTALL CASE COVER
a) Apply FIPG to the case cover, as shown.
FIPG:
Part No. 08826-00090, THREE BOND 1281 or equivalent
b) Apply sealant to the bolt threads.
Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
c) Install the case cover with the 5 bolts.
Torque: 11 Nm (115 kgf-cm, 8 ft. lbs.)
22. INSTALL L4 POSITION SWITCH, NEUTRAL POSITION SWITCH AND CENTER DIFFERENTIAL LOCK INDICATOR SWITCH WITH 3 NEW GASKETS
Torque: 37 Nm (380 kgf-cm, 27 ft. lbs.)
23. INSTALL VEHICLE SPEED SENSOR ASSEMBLY
a) Install the vehicle speed sensor driven gear to the vehicle speed sensor assembly with the clip.
b) Install a new O-ring to the vehicle speed sensor assembly.
c) Install the vehicle speed sensor assembly with the bolt.
Torque: 11 Nm (115 kgf-cm, 8 ft. lbs.)