Disassembly and Assembly

DISASSEMBLY

1. Remove drain plug and gasket from transfer cover, and drain gear oil.

2. Remove filler plug and gasket from transfer cover.

3. Remove transfer oil temperature sensor

caution

Never subject transfer oil temperature sensor to impact by dropping or hitting it.
Never twists and damage the harness of transfer oil temperature sensor.

4. Remove transfer cover mounting bolts.

5. Lightly tap transfer cover

with a plastic hammer to remove transfer cover.

6. Remove O-ring from transfer cover.

caution

Never use a tool.
Never damage transfer cover.

7. Lightly tap the metal part of oil seals

with pin punch etc. from back side of transfer cover to remove transfer cover oil seal (outer/inner).

caution

When removing, never damage the transfer cover by scooping it out with a tool.

8. Remove ring gear bearing adjusting shim (transfer cover side)

and ring gear bearing outer race (transfer cover side)

9. Perform inspection after disassembly. Refer to InspectionInspection

ASSEMBLY

1. Select the ring gear bearing adjusting shim (transfer cover side). Refer to Adjustment

2. Install the selected ring gear bearing adjusting shim (transfer cover side)

and ring gear bearing outer race (transfer cover side)

using a drift (commercial service tool).

caution

Never reuse ring gear bearing (transfer cover side).
Apply transfer oil to the ring gear bearing (transfer cover side).

3. Install the transfer cover to the transfer case, and apply anti-corrosive oil onto thread and seats on the mounting bolts. Then tighten mounting bolts to the specified torque.

For tightening torque, refer to Exploded View.

note	At this timing, O-ring installing to transfer cover is not necessary. Install O-ring after tooth contact is checked.

4. Check backlash, tooth contact, total preload and companion flange runout. Refer to Adjustment

caution

Measure the total preload without oil seals of transfer cover and transfer case.

5. Remove transfer cover to install O-ring.

6. Install O-ring to the transfer cover.

caution

Never reuse O-ring.
Apply multi-purpose grease lightly and evenly onto O-ring.
When installing O-ring, never use a tool.
Never damage O-ring.

7. Install the transfer cover to the transfer case, and apply anti-corrosive oil onto thread and seats on the mounting bolts. Then tighten mounting bolts to the specified torque.

For tightening torque, refer to Exploded View.

8. Using drift (commercial service tool), install transfer cover oil seal (outer/inner) with the directions below.

A	: Installation dimension for transfer cover oil seal (inner)
B	: Installation dimension for transfer cover oil seal (outer)

Dimension
A	: 10.3 +0.6/-0 mm (0.406 +0.024/-0 in)
B	: 0 +0.6/-0 mm (0 +0.024/-0 in)

note	The positive value is deeper than the transfer cover end face.

caution

When checking the total preload torque, measure it without the oil seal, then install the oil seal.
Never reuse the oil seal.
When installing, never incline oil seal.
Apply multi-purpose grease onto oil seal lips, and transfer oil onto the circumference of oil seal.
When installing the outer oil seal , the notch is located on the lower side.

9. Install gasket onto transfer oil temperature sensor

and install them to transfer cover.

For tightening torque, refer to Exploded View.

caution

Never reuse gasket.
Never twists and damage the harness of transfer oil temperature sensor.
If transfer oil temperature sensor is subjected to impact by dropping or hitting it, replace with new one.
Be sure to dry the sensor thread before installation.

10. Install gasket onto drain plug and install them to transfer cover.

For tightening torque, refer to Exploded View.

caution

Never reuse gasket.

11. Install gasket onto filler plug and install them to transfer cover.

For tightening torque, refer to Exploded View.

caution

Never reuse gasket.
Install filler plug after oil is filled.