Disassembly

VF4AM TRANSFER: TRANSFER ASSEMBLY: DISASSEMBLY

DISASSEMBLY

1. REMOVE HOSE
2. TEST TRANSFER RH BEARING RETAINER SUB-ASSEMBLY

(a) Remove the 5 bolts and front bearing retainer sub-assembly.

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

3. REMOVE TRANSFER COVER TYPE T OIL SEAL
(a) Using a screwdriver and hammer, remove the oil seal from the front bearing retainer sub-assembly.
4. REMOVE TRANSFER CASE COVER SUB-ASSEMBLY

(a) Remove the 4 bolts and the case cover sub-assembly.
5. REMOVE BREATHER OIL DEFLECTOR SUB-ASSEMBLY
6. REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY

(a) Using a chisel and hammer, loosen the staked part of the output shaft companion flange lock nut.
(b) Using SST to hold the output shaft companion flange, remove the output shaft companion flange lock nut.
SST: 09330-00021

(c) Using SST, remove the output shaft companion flange sub-assembly.
SST: 09950-40011
09951-04020
09952-04010
09953-04030
09954-04010
09955-04051
09957-04010
09958-04011

7. REMOVE TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL
(a) Using a screwdriver and hammer, remove the companion flange oil seal from the output shaft companion flange sub-assembly.
8. REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY
(a) Remove the rear output shaft companion flange sub-assembly using the same procedure as for the front output shaft companion flange sub-assembly.
SST: 09330-00021
SST: 09950-40011
09951-04020
09952-04010
09953-04030
09954-04010
09955-04051
09957-04010
09958-04011
9. REMOVE TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL
(a) Using a screwdriver and hammer, remove the companion flange oil seal from the output shaft companion flange sub-assembly.
10. REMOVE FRONT TRANSFER EXTENSION HOUSING SUB-ASSEMBLY

(a) Remove the 5 bolts and extension housing sub-assembly.

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

11. REMOVE TRANSFER EXTENSION HOUSING TYPE T OIL SEAL

(a) Using a screwdriver and hammer, remove the extension housing type T oil seal.
12. REMOVE TRANSFER OUTPUT SHAFT WASHER
13. REMOVE COLLAR
14. REMOVE TRANSFER REAR CASE

(a) Remove the 12 bolts and clamp.
(b) Remove the transfer rear case.

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

15. REMOVE NO. 2 TRANSFER GEAR SHIFT FORK WITH TRANSFER HIGH AND LOW CLUTCH SLEEVE

(a) Remove the bolt, gear shift fork No. 2 and high and low clutch sleeve.
16. REMOVE TRANSFER SHIFT SHAFT STOPPER

(a) Remove the bolt and shift shaft stopper.
17. REMOVE TRANSFER FRONT DRIVE SHIFT FORK SHAFT
(a) Turn the front drive shift fork shaft, and remove it from the rear case aligning the cut out position and the inter-lock pin position.
18. REMOVE OR ROLLER SHIFT INTER-LOCK PIN

(a) Using a magnetic finger, remove the 2 shift inter-lock pin.
19. REMOVE NO.2 STOPPER TRANSFER SHIFT SHAFT
20. REMOVE REAR OUTPUT SHAFT SUB-ASSEMBLY, NO. 1 GEAR SHIFT FORK, FRONT DRIVE CLUTCH SLEEVE, FRONT DRIVE CHAIN AND DRIVEN SPROCKET

(a) Using 2 screwdrivers and a hammer, tap out the shift fork shaft snap ring.

(b) Using 2 screwdrivers and a hammer, tap out the snap ring.

(d) Mount the transfer case rear in a vise.
(e) Using a plastic hammer, carefully tap the transfer case rear and remove the rear output shaft sub-assembly together with gear shift fork No. 1, front drive clutch sleeve, front drive chain and driven sprocket sub-assembly.

(f) Remove the rear output shaft sub-assembly, gear shift fork No. 1, front drive chain and driven sprocket sub-assembly.
21. REMOVE NO.2 STOPPER TRANSFER SHIFT SHAFT

(a) Remove No. 2 stopper transfer shift shaft.
22. REMOVE TRANSFER DRIVEN SPROCKET BEARING

(a) Using a press, remove the driven sprocket bearing.
23. REMOVE TRANSFER INPUT GEAR RADIAL BALL BEARING

(a) Using SST, a press and steel bar, remove the transfer input gear radial ball bearing.
SST: 09555-55010
24. REMOVE TRANSFER SHIFT ACTUATOR ASSEMBLY

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

(b) Remove the 3 bolts and transfer shift actuator assembly.
25. REMOVE TRANSFER CASE NO.1 PLUG
(a) Remove the transfer case No. 1 plug (filler plug) and gasket.
26. REMOVE TRANSFER CASE NO.1 PLUG
(a) Remove the transfer case No. 1 plug (drain plug) and gasket.
27. REMOVE TRANSFER OIL SEPARATOR SUB-ASSEMBLY

(a) Remove the 3 bolts and oil separator sub-assembly.
28. REMOVE TRANSFER CASE MAGNET
29. REMOVE TRANSFER OIL PUMP BODY SUB-ASSEMBLY

(a) Remove the 3 bolts and oil pump body sub-assembly.
30. REMOVE TRANSFER OIL PUMP BODY O-RING

(a) Using a screwdriver, remove the oil pump body O-ring.
31. REMOVE TRANSFER OIL PUMP GEAR

(a) Remove the transfer oil pump gear.
32. REMOVE LOW PLANETARY GEAR ASSEMBLY WITH INPUT SHAFT SUB-ASSEMBLY

(a) Using a snap ring expander, remove the snap ring.

(b) Remove the low planetary gear assembly with input shaft assembly.
33. REMOVE TRANSFER OUTPUT SHAFT SPACER

(a) Remove the transfer output shaft spacer.
34. REMOVE TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING
35. REMOVE TRANSFER CASE OIL SEAL
(a) Using a screwdriver and hammer, remove the transfer case oil seal.
36. REMOVE TRANSFER INPUT GEAR STOPPER SHAFT SNAP RING

(a) Using a snap ring expander, remove the input gear stopper shaft snap ring.
37. REMOVE TRANSFER INPUT GEAR STOPPER

(a) Remove the transfer input gear stopper.
38. REMOVE TRANSFER INPUT GEAR STOPPER BALL
39. REMOVE MANUAL TRANSFER PLANETARY CARRIER WASHER
40. REMOVE TRANSFER INPUT SHAFT

(a) Remove the transfer input shaft.
41. REMOVE TRANSFER NO. 1 THRUST BEARING RACE
42. REMOVE TRANSFER LOW PLANETARY GEAR BEARING
43. REMOVE TRANSFER NO. 1 INPUT SHAFT SEAL RING

(a) Remove the 2 seal rings.
44. INSPECT TRANSFER INPUT SHAFT

(a) Using a micrometer, measure the outer diameter of the input shaft journal surface.
Minimum diameter:
47.59 mm (1.8736 in.)
If the outer diameter is less than the minimum, replace the input shaft.

(b) Using a dial indicator, measure the inside diameter of the input shaft bushing.
Maximum diameter:
48.14 mm (1.8953 in.)
If the inside diameter exceeds the maximum, replace the input shaft.
45. INSPECT PLANETARY PINION GEAR THRUST CLEARANCE

(a) Using a feeler gauge, measure the thrust clearance of the planetary pinion gear.
Standard clearance:
0.11 to 0.84 mm (0.0043 to 0.0331 in.)
Maximum clearance:
0.84 mm (0.0331 in.)
If the clearance exceeds the maximum, replace the planetary gear assembly.
46. INSPECT PLANETARY PINION GEAR RADIAL CLEARANCE

(a) Using a dial indicator, measure the radial clearance of the planetary pinion gear.
Standard clearance:
0.009 to 0.038 mm (0.0004 to 0.0015 in.)
Maximum clearance:
0.038 mm (0.0015 in.)
If the clearance exceeds the maximum, replace the planetary gear assembly.
47. REMOVE TRANSFER INPUT SHAFT BEARING

(a) Using a snap ring expander, remove the input bearing shaft snap ring.
(b) Using SST and a press, remove the input shaft bearing.
SST: 09554-30011
SST: 09555-55010
48. REMOVE TRANSFER LOW PLANETARY GEAR SPLINE PIECE

(a) Using a screwdriver, remove the snap ring.
(b) Remove the low planetary gear spline piece.
49. REMOVE TRANSFER LOW PLANETARY GEAR BEARING

(a) Using SST, remove the low planetary gear bearing.
SST: 09612-65014
09612-01030
09612-01050

NOTE: Hang SST securely to the clearance between the bearing and the low planetary gear.

50. INSPECT DRIVE SPROCKET THRUST CLEARANCE

(a) Using a feeler gauge, measure the drive sprocket thrust clearance.
Standard clearance:
0.15 to 0.24 mm (0.0059 to 0.0094 in.)
Maximum clearance:
0.24 mm (0.0094 in.)
If the clearance exceeds the maximum, replace the drive sprocket.
51. INSPECT DRIVE SPROCKET RADIAL CLEARANCE

(a) Using a dial indicator, measure the radial clearance of the drive sprocket.
Standard clearance:
0.01 to 0.06 mm (0.0004 to 0.0024 in.)
Maximum clearance:
0.06 mm (0.0024 in.)
If the clearance exceeds the maximum, replace the drive sprocket, output shaft rear or needle roller bearing.
52. REMOVE TRANSFER LOW PLANETARY RING GEAR HOLE SNAP RING

(a) Using a snap ring expander, remove the snap ring.
53. REMOVE NO. 2 TRANSFER OUTPUT SHAFT SPACER
54. REMOVE TRANSFER OUTPUT SHAFT SPACER BALL
55. REMOVE CENTER DIFFERENTIAL CASE
56. REMOVE TRANSFER CLUTCH HUB

(a) Remove the transfer clutch hub.
57. REMOVE TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING
58. REMOVE TRANSFER OUTPUT SHAFT PLATE WASHER
59. REMOVE TRANSFER SYNCHROMESH SHIFTING KEY SPRING

(a) Using a screwdriver, remove the 2 shifting key springs.
60. REMOVE SYNCHROMESH SHIFTING KEY TRANSFER DRIVE
(a) Remove the 3 shifting keys.
61. REMOVE FRONT DRIVE CLUTCH SLEEVE
62. REMOVE TRANSFER SYNCHRONIZER RING SET

(a) Remove the transfer synchronizer ring.
63. REMOVE TRANSFER OUTPUT SHAFT REAR RADIAL BALL BEARING

(a) Using SST and a press, remove the output shaft rear radial ball bearing.
SST: 09555-55010
64. REMOVE NO. 1 TRANSFER OUTPUT SHAFT SPACER

(a) Remove the transfer output shaft spacer.
65. REMOVE TRANSFER DRIVE SPROCKET SUB-ASSEMBLY
66. REMOVE TRANSFER DRIVE SPROCKET BEARING
67. REMOVE TRANSFER OUTPUT SHAFT PLATE WASHER
68. INSPECT TRANSFER OUTPUT SHAFT REAR

(a) Using a micrometer, measure the outer diameter of the output shaft rear journal surface.
Standard diameter:
Part A
27.98 to 27.99 mm (1.1016 to 1.1020 in.)
Part B
31.98 to 32.00 mm (1.2591 to 1.2598 in.)
Part C
34.98 to 35.00 mm (1.3772 to 1.3780 in.)
Part D
36.98 to 37.00 mm (1.4559 to 1.4567 in.)
Minimum diameter:
Part A
27.98 mm (1.1016 in.)
Part B
31.98 mm (1.2591 in.)
Part C
34.98 mm (1.3772 in.)
Part D
36.98 mm (1.4559 in.)
If the outer diameter is less than the minimum, replace the output shaft rear.
69. INSPECT HIGH AND LOW CLUTCH SLEEVE AND GEAR SHIFT FORK NO. 2 CLEARANCE

(a) Using vernier calipers, measure the thickness of the gear shift fork No. 2 claw.
Thickness:
10 mm (0.3937 in.)
(b) Using vernier calipers, measure the groove of the high and low clutch sleeve.
Distance:
10.5 mm (0.4134 in.)
(c) Calculate a clearance between the high and low clutch sleeve and gear shift fork No. 2 clearance.
Standard clearance:
0.26 to 0.84 mm (0.0102 to 0.0331 in)
Maximum clearance:
0.84 mm (0.0331 in.)
If the clearance exceeds the maximum, replace the high and low clutch sleeve or gear shift fork No. 2.
70. INSPECT FRONT DRIVE CLUTCH SLEEVE AND NO. 1 GEAR SHIFT FORK

(a) Using vernier calipers, measure the thickness of the No. 1 gear shift fork claw.
Thickness:
10 mm (0.3937 in.)
(b) Using vernier calipers, measure the groove of the front drive clutch sleeve.
Distance:
10.5 mm (0.4134 in.)
(c) Calculate a clearance between the front drive clutch sleeve and No.1 gear shift fork.
Standard clearance:
0.26 to 0.84 mm (0.0102 to 0.0331 in.)
Maximum clearance:
0.84 mm (0.0331 in.)
If the clearance exceeds the maximum, replace the front drive clutch sleeve or No.1 gear shift fork.
71. INSPECT CENTER DIFFERENTIAL CASE AND HIGH AND LOW CLUTCH SLEEVE

(a) Check that the tip of the spline gear of the front drive clutch sleeve is not worn.
(b) Install the front drive clutch sleeve to the center differential case and check that the front drive clutch sleeve moves smoothly.
72. INSPECT CENTER DIFFERENTIAL CASE AND FRONT DRIVE CLUTCH SLEEVE

(a) Remove the transfer case plug.
74. REMOVE COMPRESSION SPRING
75. REMOVE WITH HEAD PIN
76. REMOVE TRANSFER LOW PLANETARY RING GEAR

(a) Using a screwdriver, remove the snap ring.

(b) Remove the low planetary ring gear from the front case.