Disassembly

TRANSFER: TRANSFER UNIT: DISASSEMBLY

DISASSEMBLY

1. REMOVE TRANSFER COVER GASKET






(a) Remove the transfer gasket from the transfer assembly.
2. REMOVE TRANSFER CASE BREATHER PLUG






(a) Using a screwdriver and a hammer, remove the transfer case breather plug from the No. 1 transfer case cover.
NOTE: Be careful not to damage the contact surface of No. 1 case cover.

3. REMOVE NO. 1 TRANSFER CASE COVER






(a) Remove the 8 bolts.






(b) Using a brass bar and a hammer, remove the No. 1 transfer case cover from the transfer case.
NOTE: Be careful not to damage the contact surfaces of the case and cover.

4. REMOVE BREATHER OIL DEFLECTOR






(a) Remove the bolt and breather oil deflector from the No. 1 transfer case cover.
5. REMOVE TRANSFER DYNAMIC DAMPER






(a) Remove the 3 bolts and the transfer dynamic damper from the transfer extension housing sub-assembly.
6. REMOVE TRANSFER CASE STRAIGHT PIN
(a) Remove the 4 transfer case straight pins from the transfer case.
7. REMOVE TRANSFER AND TRANSAXLE SETTING STUD BOLT
(a) Remove the 4 transfer and transaxle setting stud bolts.
8. FIX TRANSFER ASSEMBLY
(a) Fix the transfer assembly to the overhaul attachment.
9. REMOVE TRANSFER EXTENSION HOUSING DUST DEFLECTOR






(a) Using a plastic hammer, remove the transfer extension housing dust deflector from the transfer extension housing sub-assembly.
10. REMOVE TRANSFER EXTENSION HOUSING TYPE T OIL SEAL






(a) Using SST(s), remove the transfer extension housing type T oil seal from the transfer extension housing.
SST: 09308-00010
NOTE: Be careful not to damage the oil-seal-fitted surface of the housing and the inside surface of the bush.

11. REMOVE TRANSFER EXTENSION HOUSING SUB-ASSEMBLY






(a) Remove the 4 bolts.






(b) Using a plastic hammer, remove the transfer extension housing sub- assembly from the transfer case.
12. INSPECT PRELOAD






(a) Using SST(s) and a torque wrench, check the initial torque with the backlash range.
SST: 09326-20011
Torque: 0.9 to 1.4 Nm (9 to 14 kgf-cm, 8.0 to 12.4 in-lbf)
HINT: Use a torque wrench with a fulcrum length of 160 mm (6.30 in.)

(b) Using SST(s) and a torque wrench, check the initial torque while the driven pinion is in contact with the ring gear face.
SST: 09326-20011
Preload - Torque: + 0.15 to 0.30 Nm (+ 1.6 to 3.1 kgf-cm, + 1.3 to 2.7 in-lbf)
HINT: Use a torque wrench with a fulcrum length of 160 mm (6.30 in.)

13. REMOVE CTR DIFFERENTIAL LOCK SLEEVE






(a) Using snap ring pliers, remove the shaft snap ring.






(b) Using SST(s), remove the CTR differential lock sleeve.
SST: 09308-00010
14. REMOVE O-RING






(a) Using a screwdriver with the tip protected by vinyl tape, remove the O-ring from the CTR differential lock sleeve.
NOTE: Be careful not to damage the lock sleeve's groove for the O-ring.

15. REMOVE TRANSFER CASE OIL SEAL






(a) Using SST(s), remove the transfer case oil seal from the case.
SST: 09308-00010
NOTE: Be careful not to damage the oil-seal-fitted surface of the case.

16. REMOVE TRANSFER RH BEARING RETAINER OIL SEAL






(a) Using SST(s), remove the transfer RH bearing retainer oil seal from the transfer RH bearing retainer sub-assembly.
SST: 09308-00010
NOTE: Be careful not to damage the oil-seal-fitted surface of the retainer.

17. REMOVE TRANSFER RH BEARING RETAINER SUB-ASSEMBLY






(a) Remove the 7 bolts from the transfer RH bearing retainer sub-assembly.






(b) Using SST, make a clearance between the transfer RH bearing retainer sub-assembly and the transfer case.
SST: 09950-00020
(c) Remove the SST.






(d) Using SST, remove the transfer RH bearing retainer sub-assembly from the transfer case.
SST: 09520-10021
18. REMOVE O-RING






(a) Using a screwdriver with the tip protected by vinyl tape, remove the 2 O-rings from the transfer RH bearing retainer sub-assembly.
NOTE: Be careful not to damage the retainer's grooves for the O-rings.

19. REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING






(a) Fix the transfer RH bearing retainer sub-assembly in a vise.
(b) Using SST(s), remove the center differential case tapered roller bearing RH outer race, transfer ring gear mounting case washer No. 2 and right bearing retainer oil seal No. 2 from the transfer RH bearing retainer sub-assembly.
SST: 09308-00010
NOTE: Be careful not to damage the oil-seal-fitted surface of the transfer RH bearing retainer sub-assembly.

20. REMOVE SIDE GEAR SHAFT HOLDER BEARING






(a) Using snap ring pliers, remove the side gear shaft holder hole snap ring.
(b) Remove the side gear shaft holder bearing from the transfer RH bearing retainer sub-assembly.
21. REMOVE TRANSFER RING GEAR MOUNTING CASE






(a) Remove the transfer ring gear mounting case from the transfer case.
22. REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING






(a) Using SST(s), remove the inner race of the center differential case tapered roller bearing from the transfer ring gear mounting case.
NOTE: Apply grease to the screw thread and tip of the SST(s) before use.





(b) When the roller comes off due to deformation of the gauge, completely remove the roller and remaining inner races of the center differential case tapered roller bearing from the transfer ring gear mounting case.
NOTE: Apply grease to the screw thread and tip of the SST(s) before use.





(c) Using SST(s), remove the inner race of the center differential case tapered roller bearing from the transfer ring gear mounting case.
NOTE: Apply grease to the screw thread and tip of the SST(s) before use.





(d) When the roller comes off due to deformation of the gauge, completely remove the roller and remaining inner races of the center differential case tapered roller bearing from the transfer ring gear mounting case.
NOTE: Apply grease to the screw thread and tip of the SST(s) before use.

23. REMOVE RING GEAR






(a) Put matchmarks on the transfer ring gear mounting case and the ring gear.
(b) Remove the 12 bolts.






(c) Using a plastic hammer, remove the ring gear by tapping around its periphery.
NOTE: Do not damage the teeth of the ring gear.

24. REMOVE TRANSFER GEAR NUT






(a) Using SST(s) and a hammer, unstake the transfer gear nut.
SST: 09930-00010






(b) Using SST(s), remove the transfer gear nut.






(c) Using a press, remove the driven pinion, transfer driven pinion rear bearing inner race and transfer pinion bearing spacer.
- Put shop cloths around to help prevent the driven pinion from bearing dropped.
- Place something like wood blocks under the case to keep it level.

25. REMOVE TRANSFER DRIVEN PINION FRONT BEARING






(a) Using SST(s) and a press, remove the transfer driven pinion front bearing inner race from the driven pinion.
SST: 09950-00020
26. REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING






(a) Using a brass bar and a hammer, lightly strike the center differential case tapered roller bearing LH outer race at 2 positions to remove it from the transfer case.
27. REMOVE TRANSFER OUTPUT SHAFT WASHER
(a) Remove the ring gear mounting case plate washer from the transfer case.
28. REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING






(a) Using brass bar and a hammer, lightly strike the transfer driven pinion front bearing outer race at 2 points to remove it from the transfer case.
29. REMOVE RING GEAR MOUNTING CASE PLATE WASHER
(a) Remove the transfer output washer from the transfer case.
30. REMOVE TRANSFER DRIVEN PINION REAR BEARING






(a) Using a brass bar and a hammer, lightly strike the transfer driven pinion rear bearing outer race at 2 points to remove it from the transfer case.