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 STRAIGHT SCREW PLUG WITH 3 GASKETS





3. REMOVE FRONT BEARING RETAINER
Remove the 5 bolts and front bearing retainer.

HINT: If necessary, tap the front bearing retainer with a plastic hammer to remove it.

4. REMOVE TRANSFER UPPER COVER
Remove the 4 bolts, transfer upper cover and oil deflector.
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 a SST, remove the front companion flange.
SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04051, 09957-04010, 09958-04011)
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 front 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 SHAFT HEAD NO. 2
a. Using a pin punch and hammer, tap out the slotted pin from the high and low fork shaft.
b. Remove the shaft head No. 2.





10. 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.





11. 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 spring and ball.
12. REMOVE NO. 2 GEAR SHIFT FORK AND HIGH AND LOW SHIFT FORK SHAFT





a. Remove 2 screwdrivers and a hammer, tap out the snap ring





b. Using a pin punch and hammer, tap out the slotted spring pin from the No. 2 rear shift fork.





c. Remove the No. 2 gear shift fork and high and low shift fork shaft.

13. REMOVE ACTUATOR ASSEMBLY





a. Using 2 screwdrivers and a hammer, tap out the 2 snap rings from the gear shift fork shaft of the actuator assembly.
b. Remove the 3 bolts and actuator assembly.
c. Remove the O-ring, No. 1 and No. 2 4WD position switches with the 2 gaskets from the actuator assembly.

14. 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 diff. lock fork.





c. Remove the bolt and shift shaft stopper.





d. Remove the gear shift fork shaft.





e. Using a magnetic finger, remove the 2 No. 2 shift interlock pins from the No. 1 gear shift fork and center diff. lock.

15. REMOVE REAR OUTPUT SHAFT ASSEMBLY, NO. 1 GEAR SHIFT FORK, CENTER DIFF. LOCK FORK, DRIVEN SPROCKET ASSEMBLY AND FRONT DRIVE CHAIN
a. Using a snap ring expander, remove the output shaft snap ring.





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





e. Remove the front driven chain, driven sprocket assembly, center diff. lock fork and No. 1 gear shift fork from the rear output shaft assembly.





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





18. REMOVE OIL PUMP GEAR FROM FRONT CASE





19. 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.





20. 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.





21. REMOVE OUTPUT SHAFT NEEDLE ROLLER BEARING FROM INPUT SHAFT





22. 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.





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








INSPECT SWITCH
Check that there is continuity between terminals,
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 pin and spring.
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 LOW PLANETARY GEAR BEARING, NO. 2 THRUST BEARING RACE 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 cut-out 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 to the front case.

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 REAR OUTPUT SHAFT ASSEMBLY, NO. 1 GEAR SHIFT FORK, CENTER DIFF. LOCK FORK, DRIVEN SPROCKET ASSEMBLY AND FRONT DRIVE CHAIN





a. Install the No. 1 gear shift fork, center diff. 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.

11. INSTALL GEAR SHIFT FORK SHAFT





a. Using a magnetic finger, install the 2 No. 2 shift interlock pins top the No. 1 gear shift fork and center diff. lock fork.





b. Install the gear shift fork shaft.





c. Make sure both interlock pins are in both shift fork shaft detents.





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





g. Using a hexagon wrench, install the 2 straight screw plugs to the No. 1 gear shift fork and center diff. lock fork.
Torque: 19 Nm (190 kgf-cm, 14 ft. lbs.)





h. Using a screwdriver and hammer, drive in the 3 snap rings to the gear shift fork shaft of the actuator assembly.

12 INSTALL THE ACTUATOR ASSEMBLY
a. Install a new o-ring, no. 1 and no. 2 4wd position switches with 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.)





c. Using a screwdriver and hammer, drive in the 2 snap rings to the gear shift fork shaft of the actuator assembly.

13. INSTALL HIGH AND LOW SHIFT FORK SHAFT, AND NO. 2 GEAR SHIFT FORK





a. Install the high and low shift fork shaft and No. 2 gear shift fork.

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





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





a. Install the ball and spring.
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 snap ring to the gear shift fork shaft.





15. INSTALL REAR CASE
a. Apply FIPG to the rear case.
FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent
b. Assemble the rear case and 2 clamps with the 12 bolts.
Torque: 28 Nm (285 kgf-cm, 21 ft. lbs.)





16. INSTALL SHIFT HEAD NO. 2
a. Install the shift head No. 2.
b. Using a pin punch and hammer, drive in the slotted spring pin to the shift head No. 2.
17. 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 washers.





18. INSTALL EXTENSION HOUSING
a. Apply FIPG to the extension housing.
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.)





19. 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.
20. INSTALL REAR COMPANION FLANGE
Install the rear companion flange in the same way as the front companion flange.
21. INSTALL TRANSFER UPPER COVER
Install a new oil deflector and the transfer upper cover with the 4 bolts.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)





22. INSTALL FRONT BEARING RETAINER
a. Apply FIPG to the front bearing retainer.
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 front bearing retainer with the 5 bolts.
Torque: 11 Nm (115 kgf-cm, 8 ft. lbs.)
23. INSTALL L4 POSITION SWITCH, NEUTRAL POSITION SWITCH AND STRAIGHT SCREW PLUG WITH 3 NEW GASKETS
Torque: 37 Nm (380 kgf-cm, 27 ft. lbs.)
24. 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.)