Disassembly

MF1A TRANSFER / 4WD / AWD: TRANSFER ASSEMBLY: DISASSEMBLY

1. REMOVE TRANSFER AND TRANSAXLE SETTING STUD BOLT

(a) Remove the 4 transfer and transaxle setting stud bolts.

2. REMOVE NO. 2 TRANSFER CASE PLUG

(a) Remove the No. 2 transfer case plug.

(b) Remove the gasket from the No. 2 transfer case plug.

3. REMOVE NO. 1 TRANSFER CASE PLUG

(a) Remove the No. 1 transfer case plug.

(b) Remove the gasket from the No. 1 transfer case plug.

4. REMOVE TRANSFER DRAIN PLUG

(a) Remove the transfer drain plug.

(b) Remove the gasket from the transfer drain plug.

5. REMOVE TRANSFER CASE BREATHER PLUG

(a) Using a hammer and chisel, slightly raise the transfer case breather plug.

(b) Using a screwdriver, remove the transfer case breather plug.

6. REMOVE TRANSFER CASE COVER SUB-ASSEMBLY

(a) Remove the 8 bolts.

(b) Using a brass bar and a hammer, remove the transfer case cover.

Text in Illustration

NOTICE:
Place the brass bar on the rib protruding from the case.

7. REMOVE BREATHER OIL DEFLECTOR

(a) Remove the bolt and breather oil deflector.

8. REMOVE TRANSFER CASE STRAIGHT PIN

(a) Remove the 4 transfer case straight pins.

9. SECURE TRANSFER ASSEMBLY

(a) Attach the transfer onto the overhaul attachment.

10. REMOVE TRANSFER EXTENSION HOUSING DUST DEFLECTOR

(a) Using a plastic hammer, remove the transfer extension housing dust deflector.

HINT
Perform this step only when replacing the transfer extension housing dust deflector or transfer extension housing.

11. REMOVE TRANSFER EXTENSION HOUSING TYPE T OIL SEAL

(a) Using SST, remove the transfer extension housing type T oil seal from the transfer extension housing.

Text in Illustration

SST : 09308-00010

NOTICE:
Do not damage the oil seal contact surface on the extension housing.

12. REMOVE TRANSFER EXTENSION HOUSING SUB-ASSEMBLY

(a) Remove the 4 bolts.

(b) Using a plastic hammer, remove the transfer extension housing.

13. REMOVE TRANSFER CASE OIL SEAL

(a) Using SST, remove the transfer case oil seal from the transfer case.

Text in Illustration

SST : 09308-00010

NOTICE:
Do not damage the oil seal contact surface on the case.

14. REMOVE TRANSFER CASE RH OIL SEAL

(a) Using SST, remove the transfer case RH oil seal from the transfer case.

Text in Illustration

SST : 09308-00010

NOTICE:
Do not damage the oil seal contact surface on the case.

15. INSPECT PRELOAD

(a) Using SST and a torque wrench, measure the preload of the backlash between the transfer driven pinion and transfer ring gear.

SST : 09326-20011

Preload (at Starting):

HINT
* The "with SST" torque value is effective when using SST with a fulcrum length of 50 mm (1.97 in.).
* The "with SST" torque value is effective when using a torque wrench with a fulcrum length of 130 mm (5.12 in.) Service Precautions.
* The "with SST" torque value is effective when SST is parallel to the torque wrench.

(b) Using SST and a torque wrench, measure the total preload.

SST : 09326-20011

Preload (at Starting):

HINT
* The "with SST" torque value is effective when using SST with a fulcrum length of 50 mm (1.97 in.).
* The "with SST" torque value is effective when using a torque wrench with a fulcrum length of 130 mm (5.12 in.) Service Precautions.
* The "with SST" torque value is effective when SST is parallel to the torque wrench.

If necessary, disassemble and inspect the transfer assembly.

16. INSPECT RING GEAR BACKLASH

(a) Using a dial indicator, check the backlash of the transfer ring gear.

Backlash:

0.14 to 0.25 mm (0.00552 to 0.00984 in.)

If the backlash is not within the specification, adjust the side bearing preload or repair as necessary.

HINT
Check at least 3 positions on the circumference of the ring gear.

17. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVEN PINION

(a) Coat 3 or 4 teeth at 4 different positions on the ring gear with Prussian blue.

(b) Rotate the ring gear 10 times more.

(c) Rotate the ring gear to inspect the tooth contact pattern.

Text in Illustration

If the tooth contact pattern is not correct, select a new transfer output shaft washer that is thicker or thinner as necessary and recheck.

18. REMOVE TRANSFER BEARING CAP

(a) Remove the 2 bolts and transfer bearing cap.

19. REMOVE NO. 1 TRANSFER OUTPUT SHAFT SPACER

(a) Using SST, a screwdriver and a hammer, remove the No. 1 transfer output shaft spacer.

Text in Illustration

SST : 09504-22011

NOTICE:
Do not damage the transfer case.

20. REMOVE NO. 2 TRANSFER RING GEAR MOUNTING CASE WASHER

21. REMOVE TRANSFER RING GEAR MOUNTING CASE

(a) Remove the transfer ring gear mounting case.

22. REMOVE TRANSFER DRIVEN PINION

(a) Using SST and a hammer, unstake the transfer gear nut.

SST : 09930-00010

HINT
* Use SST with the flat side facing outward.
* Do not machine the tip of SST with a grinder, etc.

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

Text in Illustration

SST : 09326-20011

SST : 09556-16030

(c) Using a press, press out the transfer driven pinion, transfer driven pinion rear bearing (inner race) and transfer pinion bearing spacer.

NOTICE:
* Place a piece of cloth under the transfer case to prevent the driven pinion from dropping out of the bearing.
* Use wooden blocks or similar objects under the case to keep it level.

23. REMOVE TRANSFER DRIVEN PINION FRONT BEARING

(a) Using SST and a press, press out the transfer driven pinion front bearing (inner race).

Text in Illustration

SST : 09950-00020

(b) Using a brass bar and a hammer, tap the 2 positions shown in the illustration on the driven pinion front bearing (outer race) to remove it.

24. REMOVE TRANSFER DRIVEN PINION REAR BEARING

(a) Using a brass bar and a hammer, tap the 2 positions shown in the illustration on the transfer driven pinion rear bearing (outer race) to remove it.

25. REMOVE TRANSFER OUTPUT SHAFT WASHER

(a) Remove the transfer output shaft washer.

26. REMOVE RING GEAR MOUNTING CASE BEARING

(a) Remove the ring gear mounting case bearing (RH side).

(1) Remove the ring gear mounting case bearing (outer race).

(2) Using SST, remove the ring gear mounting case bearing (inner race).

Text in Illustration

SST : 09950-40011

09951-04010

09952-04010

09953-04020

09954-04010

09955-04061

09957-04010

09958-04011

SST : 09950-60010

09951-00440

NOTICE:
Use SST (09953-04020) after applying grease to its threads and tip.

(b) Remove the ring gear mounting case bearing (LH side).

(1) Using a brass bar and a hammer, tap the 2 positions shown in the illustration on the ring gear mounting case bearing (outer race) to remove it.

(2) Remove the ring gear mounting case plate washer.

(3) Using SST, remove the ring gear mounting case bearing (inner race).

Text in Illustration

SST : 09950-40011

09951-04010

09952-04010

09953-04020

09954-04010

09955-04061

09957-04010

09958-04011

SST : 09950-60010

09951-00400

NOTICE:
Use SST (09953-04020) after applying grease to its threads and tip.

27. INSPECT RING GEAR RUNOUT

(a) Place the transfer ring gear mounting case on the V-blocks.

(b) Using a dial indicator, check the runout of the ring gear.

Maximum runout:

0.06 mm (0.00236 in.)

If the runout is more than the maximum, replace the ring gear or transfer ring gear mounting case with a new one.

28. REMOVE TRANSFER RING GEAR

(a) Fix the transfer ring gear mounting case in a vise between aluminum plates.

NOTICE:
Do not overtighten the vise.

(b) Put matchmarks on the transfer ring gear mounting case and transfer ring gear.

Text in Illustration

NOTICE:
Do not damage the transfer ring gear teeth.