Part 1
OVERHAUL1. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
2. REMOVE FRONT DRIVE SHAFT ASSY RH
3. REMOVE TRANSFER CASE NO.1 PLUG
a. Remove the No.1 plug.
b. Remove the gasket from the plug.
4. REMOVE TRANSFER CASE NO.2 PLUG
a. Remove the No.2 plug.
b. Remove the gasket from the plug.
5. REMOVE TRANSFER DRAIN PLUG
a. Remove the drain plug and drain the oil.
b. Remove the gasket from the drain plug.
6. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
a. Remove the 6 bolts and rear engine mounting bracket.
7. REMOVE TRANSFER STIFFENER PLATE RH
a. Remove the 2 bolts and right stiffener plate.
8. REMOVE TRANSFER ASSY
a. Remove the 2 bolts and 6 nuts.
b. Using a plastic hammer, drive out the transfer assy from the transaxle assy.
NOTICE:
^ Disconnect the transfer assy from the transaxle assy without tilting.
^ When moving the transfer assy, do not hold the oil seal parts on both sides of the assy.
9. REMOVE TRANSFER COVER GASKET
a. Remove the gasket from the transfer assy.
10. REMOVE DIFFERENTIAL SIDE GEAR INTERMEDIATE SHAFT NO.2
a. Remove the intermediate shaft No.2 from the transfer assy.
11. REMOVE TRANSFER CASE COVER NO.1
a. Remove the 8 bolts.
b. Using a brass bar and a hammer, remove the case cover from the case.
NOTICE: Be careful not to damage the mating surfaces of the case and cover.
12. REMOVE BREATHER OIL DEFLECTOR
a. Remove the bolt and breather oil deflector from the case cover.
13. REMOVE TRANSFER DYNAMIC DAMPER
a. Remove the 3 bolts and the dynamic damper from the extension housing.
14. REMOVE TRANSFER CASE STRAIGHT PIN
15. REMOVE TRANSFER & TRANSAXLE SETTING STUD BOLT
16. FIX TRANSFER ASSY
a. Fix the transfer assy to the overhaul attachment.
17. REMOVE TRANSFER EXTENSION HOUSING DUST DEFLECTOR
a. Using a plastic hammer, remove the dust deflector from the extension housing.
18. REMOVE TRANSFER EXTENSION HOUSING TYPE T OIL SEAL
a. Using SST, remove the oil seal from the extension housing.
SST 09308-00010
NOTICE: Be careful not to damage the oil-seal-fitted surface of the housing and the inside surface of the bush.
19. REMOVE TRANSFER EXTENSION HOUSING SUB-ASSY
a. Remove the 4 bolts.
b. Using a plastic hammer, remove the extension housing from the case.
20. INSPECT PRELOAD
a. Using SST and a torque wrench, check the initial torque within the backlash range.
SST 09326-20011
Torque: 0.9 - 1.3 Nm (9 - 13 kgf-cm, 0.7 - 1.0 ft. lbs.)
b. Using SST and a torque wrench, check the initial torque while the driven pinion is contact with the ring gear face.
SST 09326-20011
Torque: 1.0 - 1.6 Nm (10 - 16 kgf-cm, 0.7 - 1.2 ft. lbs.)
21. INSPECT BACKLASH
a. Set the dial gauge perpendicular to the tooth face of the ring gear, fix the driven pinion and check the backlash while moving the gear.
Backlash: 0.1 - 0.15 mm (0.0039 - 0.0059 inch)
NOTICE: Check it at 3 points or more on the gear periphery.
22. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVEN PINION
a. Apply red lead primer thinly and uniformly to both faces of the ring gear and rotate it several times.
NOTICE: Check the tooth contact on the ring gear at 4 places or more.
b. Proper washer location is shown in the illustration.
23. REMOVE CTR DIFFERENTIAL LOCK SLEEVE
a. Using a snap ring pliers, remove the shaft snap ring.
b. Using SST, remove the center differential lock sleeve.
SST 09308-00010
24. REMOVE O-RING
a. Using a screwdriver with the tip protected by taping, remove the O-ring from the center differential lock sleeve.
NOTICE: Be careful no to damage the lock sleeve's groove for the O-ring.
25. REMOVE TRANSFER CASE OIL SEAL
a. Using SST, remove the oil seal from the case.
SST 09308-00010
NOTICE: Be careful not to damage the oil-seal-fitted surface of the case.
26. REMOVE TRANSFER RH BEARING RETAINER OIL SEAL
a. Using SST, remove the oil seal from the right bearing retainer.
SST 09308-00010
NOTICE: Be careful not to damage the oil seal-fitted surface of the retainer.
27. REMOVE TRANSFER RH BEARING RETAINER SUB-ASSY
a. Remove the 7 bolts from the right bearing retainer.
b. Using a screwdriver and a hammer, make a clearance between the right bearing retainer and the transfer case.
c. Using SST, remove the right bearing retainer from the transfer case.
SST 09520-10021
28. REMOVE TRANSFER RH BEARING RETAINER O-RING
a. Using a screwdriver with the tip protected by taping, remove the O-ring from the right bearing retainer.
NOTICE: Be careful not to damage the retainer's groove for the O-ring.
29. REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING
a. Hold the right bearing retainer in a vise.
b. Using SST, remove the outer race, washer and oil seal from the right bearing retainer.
SST 09308-00010
NOTICE: Be careful not to damage the oil-seal-fitted surface of the retainer.
30. REMOVE SIDE GEAR SHAFT HOLDER BEARING
a. Using a snap ring pliers, remove the side gear shaft holder hole snap ring.
b. Remove the side gear shaft holder bearing from the right bearing retainer.
31. REMOVE CENTER DIFFERENTIAL CONTROL COUPLING ASSY
a. Remove the center differential control coupling assy from the case.
32. REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING
a. RH side:
Using SST, remove the inner race of the center differential case tapered roller bearing from the center differential control coupling assy.
SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-600110 (09951-00420)
NOTICE: Apply grease to the screw thread and tip of the SST before use.
HINT When the roller is come off due to deformation of the gauge, completely remove the roller and take away remaining inner races of the center differential case tapered roller bearing from the center differential control coupling assy.
SST 09950-00020, 09950-00030, 09950-60010 (09951-00430)
NOTICE: Apply grease to the screw thread and tip of the SST before use.
b. LH side:
Using SST, remove the inner race of the center differential case tapered roller bearing from the center differential control coupling assy.
SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010 (09951-00360)
NOTICE: Apply grease to the screw thread and tip of the SST before use.
HINT When the roller is come off due to deformation of the gauge, completely remove the roller and take away remaining inner races of the center differential case tapered roller bearing from the center differential control coupling assy.
SST 09950-00020, 09950-00030, 09950-60010 (09951-00360)
NOTICE: Apply grease to the screw thread and tip of the SST before use.
33. INSPECT RUNOUT OF RING GEAR
a. Set the center differential control coupling assy on V blocks and check vibration of the ring rear using a dial gauge.
Maximum runout: 0.1 mm (0.004 inch)
34. REMOVE RING GEAR
a. Put matchmarks on the center differential control coupling assy and the ring gear.
b. Remove the 12 bolts.
c. Using a plastic hammer, remove the ring gear by tapping around its periphery.
35. INSPECT RUNOUT OF CENTER DIFFERENTIAL CONTROL COUPLING ASSY
a. Using a dial indicator, check the ring gear runout.
Maximum runout: 0.07 mm (0.0028 inch)
36. REMOVE DRIVEN PINION
a. Using SST, unstake the gear nut.
SST 09930-00010
b. Using SST, remove the gear nut.
SST 09326-20011, 09556-16030
c. Using a press, remove the driven pinion, bearing rear and spacer.
NOTICE:
^ Put a shop rug in the case to prevent the driven pinion from being dropped.
^ Place something like wood blocks under the case to keep it level.
37. REMOVE BEARING (FOR TRANSFER DRIVEN PINION FRONT)
a. Using SST and a press, remove the inner race from the driven pinion.
SST 09950-00020
38. REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING
a. Using a brass bar and a hammer, remove the outer race.
39. REMOVE RING GEAR MOUNTING CASE PLATE WASHER
40. REMOVE BEARING (FOR TRANSFER DRIVEN PINION FRONT)
a. Using a brass bar and a hammer, lightly strike the outer race at 2 points to remove it from the case.
41. REMOVE TRANSFER OUTPUT WASHER
42. REMOVE BEARING (FOR TRANSFER DRIVEN PINION REAR)
a. Using a brass bar and a hammer, remove the outer race.
43. INSTALL BEARING (FOR TRANSFER DRIVEN PINION REAR)
a. Using SST and a press, install the outer race to the case.
SST 09950-60010 (09951-00620), 09950-70010 (09951-07150)
NOTICE: Place something like wood blocks under the case to keep it level.
44. INSTALL TRANSFER OUTPUT WASHER
a. Install the washer to the case.
HINT Reuse the washer used before disassembly.
45. INSTALL BEARING (FOR TRANSFER DRIVEN PINION FRONT)
a. Install the outer race to the case with SST, bolt and nut.
SST 09950-60020 (09951-00750, 09951-00770, 09951-00810), 09316-60011 (09316-00061)
46. INSTALL RING GEAR MOUNTING CASE PLATE WASHER
a. Install the washer to the case.
HINT Reuse the washer used before disassembly.
47. INSTALL CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING
a. Using SST and a press, install the outer race to the case.
SST 09950-70010 (09951-07200), 09316-60011 (09316-00021)
48. INSTALL BEARING (FOR TRANSFER DRIVEN PINION FRONT)
a. Using SST and a press, install the inner race to the driven pinion.
SST 09316-60011 (09316-00041)
49. INSTALL DRIVEN PINION
a. Install the driven pinion to the case.
b. Install a new bearing spacer and a new bearing rear to the driven pinion.
c. Using SST, tighten a new gear nut with a standard torque.
SST 09326-20011, 09556-16030
Torque: 327 Nm (3,334 kgf-cm, 241 ft. lbs.)
NOTICE: Do not stake the gear nut.
50. INSPECT AND ADJUST DRIVEN PINION PRELOAD
a. Using SST and a torque wrench, measure the initial torque of the driven pinion.
SST 09326-20011
Preload (at starting):
New bearing: 0.9 - 1.4 Nm (9 - 14 kgf -cm, 8.0 - 12.0 inch lbs.)
Used bearing: 0.8 - 1.1 Nm (8 - 11 kgf-cm, 7.0 - 9.7 inch lbs.)
NOTICE: Measure it after rotating the bearing in both advance and reverse directions to make it fit.
b. If the preload is too large, replace the bearing spacer with new one.
c. If the preload is too small, repeatedly adjust the preload by tightening the lock nut 5 to 10 degrees at a time until the standard value is obtained.
d. If the preload is insufficient even though the tightening torque of the lock nut exceeds the maximum of the standard value, loosen the lock nut and apply gear oil SAE 90 (GL-5) to the lock nut and the screw thread and base of the driven pinion. And then repeat the preceding operation. If the tightening torque is smaller than the standard, replace the bearing spacer with new one and adjust it.
SST 09326-20011, 09556-16030
Torque: 378 Nm (3,855 kgf-cm, 279 ft. lbs.)
51. INSTALL RING GEAR
a. Heat the ring gear in boiling water to 90 - 100° C (194 - 212° F).
b. Completely remove grease and moisture on the mating surfaces of the ring gear and the center differential control coupling assy.
c. Align the matchmarks on the ring gear and center differential control coupling assy and quickly assemble them.
d. Tighten the12 bolts.
Torque: 77.5 Nm (791 kgf-cm, 57 ft. lbs.)
52. INSTALL CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING
a. RH side:
Using SST and a press, install the inner race of the center differential case tapered roller bearing to the center differential control coupling assy.
SST 09506-35010, 09950-60010 (09951-00430)
NOTICE: When replacing the inner race, replace the outer race, too.
b. LH side:
Using SST and a press, install the inner race of the center differential case tapered roller bearing to the center differential control coupling assy.
SST 09223-00010
NOTICE: When replacing the inner race, replace the outer race, too.
53. INSTALL CENTER DIFFERENTIAL CONTROL COUPLING ASSY
a. Install the center differential control coupling assy to the case.
NOTICE: Damage to the spline, bearing's rotating surface and gear face may cause decrease in their strength. Care should be taken at the time of installation.