Transfer Case: Service Precautions

PRECAUTION
^ Before disassembly, clean the transfer assy and remove any deposited sand or mud to prevent it from entering the inside of the transfer during disassembly and assembly.
^ When removing any light alloy part such as a transfer cover, do not pry it off with a tool like a screwdriver but tap it out with a plastic hammer.
^ Always organize the removed parts properly and protect them away from dust.
^ After cleaning and drying completely before installation, apply hypoid gear oil to each part. Do not use alkaline chemicals when cleansing aluminum or rubber parts and ring gear set bolts.
Also, do not use any cleansing oil (ex. white gasoline) to clean the rubber parts such as oil seals.
^ Sufficiently apply hypoid gear oil to any sliding surface or rotating part.
^ Do not directly hold a part by vise. Make sure to put an aluminum sheet between them. Replace any damaged or deformed snap ring with new one.
^ If mating surface of the case is scratched, it may cause oil leakage. Therefore, carefully avoid such damage when handling.
^ Using a razor blade and gasket scraper, remove old FIPG from seal surface.
^ Clean all the components to remove the redundant FIPG completely.
^ Clean sealing surface with solvent so that any residue does not remain on the seal surface.
^ Apply FIPG in an approx. 1.2 mm (0.047 inch) diameter of bead state along the sealing surface.
^ Be sure to assemble parts within 10 minutes of application. Otherwise, the FIPG must be re moved and reapplied.
^ Do not fill oil immediately after installing sealed parts. Leave it 1 hour or more.
^ Scratches on the contact surface with an oil seal or gasket may result in oil leakage. Handle with care to prevent such damage.
^ When press-fitting an oil seal, take care to prevent the oil seal lip and its periphery from being damaged.