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Disassembly and Assembly
 
 
DISASSEMBLY
 
 
1. Remove transfer cover. Refer to Disassembly and Assembly.
2. Remove ring gear shaft assembly. Refer to Disassembly and Assembly.
3. Remove drive pinion assembly. Refer to Disassembly and Assembly.
4. Remove O-ring from transfer case.
caution
  • Never use a tool.
  • Never damage transfer case.
5. Remove transfer case oil seals .
cautionNever damage transfer case.
6. Remove baffle plate .
7. Remove the ring gear bearing adjusting shim (transfer case side) and ring gear bearing outer race (transfer case side) by tapping from the 2 cutouts () on the transfer case.
cautionNever damage transfer case.
8. Remove plug and gasket.
9. Perform inspection after disassembly. Refer to Inspection.
 
 
ASSEMBLY
 
 
1. Select the ring gear bearing adjusting shim (transfer case side). Refer to Adjustment.
2. Install the selected ring gear bearing adjusting shim (transfer case side) and ring gear bearing outer race (transfer case side) using drift (A) (commercial service tool).
caution
  • Never reuse ring gear bearing (transfer case side).
  • Apply transfer oil to the ring gear bearing (transfer case side).
3. Install baffle plate .
4. Install ring gear shaft assembly. Refer to Disassembly and Assembly.
cautionProtect transfer case oil seals beforehand from being damaged by the spline of ring gear shaft.
5. Install drive pinion assembly. Refer to Disassembly and Assembly.
6. Install transfer cover to check and adjust each part. Refer to Disassembly and Assembly.
noteAt this timing, O-ring installing to transfer cover is not necessary. Install O-ring after backlash and tooth contact are checked.
7. Check backlash, tooth contact, total preload and companion flange runout. Refer to Adjustment.
cautionMeasure the total preload without oil seals of transfer cover and transfer case.
8. Reinstall transfer cover to install O-ring. Refer to Disassembly and Assembly.
9. Install transfer case oil seals using drift (commercial service tool).
A: 15.8 mm (0.622 in)
B: 4.65 mm (0.1831 in)
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 the oil seal.
  • Never damage oil seals by spline of ring gear shaft.
10. After installing transfer case oil seals to transfer case, remove wrapped vinyl from the spline of ring gear shaft.
11. Install O-ring to the transfer case.
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.