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Disassembly and Assembly
 
 
DISASSEMBLY
 
 
1. Remove transfer cover assembly. Refer to Disassembly and Assembly.
2. Remove ring gear bearing outer race (transfer cover side) and ring gear bearing adjusting shim (transfer cover side) from the transfer cover. Refer to Disassembly and Assembly.
3. Remove ring gear shaft assembly from the transfer case.
4. Remove ring gear bearing outer race (transfer case side) and ring gear bearing adjusting shim (transfer case side) from the transfer case. Refer to Disassembly and Assembly.
5. Remove ring gear bearing inner race (transfer cover side) from ring gear shaft using drift (A) (commercial service tool) and separator (B) (commercial service tool).
6. Remove ring gear bearing inner race (transfer case side) from ring gear shaft with drift (A) [SST: ST33061000 (J-8107-2)] and puller (B) (commercial service tool).
7. Remove the ring gear mounting bolts.
8. Lightly tap ring gear with a plastic hammer to remove ring gear from the ring gear shaft.
9. Remove ring gear shaft oil seal from the ring gear shaft with the puller (A) [SST: KV381054S0 (J-34286)].
10. Perform inspection after disassembly. Refer to Inspection.
 
 
ASSEMBLY
 
 
1. Using drift (A) (commercial service tool), install ring gear shaft oil seal within the dimension (L) shown as follows.
L: 2.0 +0.6/−0 mm (0.079 +0.024/−0 in)
noteThe positive value is deeper than the ring gear shaft end face.
caution
  • 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.
2. Select ring gear bearing adjusting shim (transfer case side) and ring gear bearing adjusting shim (transfer cover side). Refer to Adjustment.
3. Assemble the selected ring gear bearing adjusting shim (transfer case side) and ring gear bearing outer race (transfer case side) to transfer case. Refer to Disassembly and Assembly.
caution
  • Never reuse ring gear bearing (transfer case side).
  • Apply transfer oil to the ring gear bearing (transfer case side).
4. Assemble the selected ring gear bearing adjusting shim (transfer cover side) and ring gear bearing outer race (transfer cover side) to transfer cover. Refer to Disassembly and Assembly.
caution
  • Never reuse ring gear bearing (transfer cover side).
  • Apply transfer oil to the ring gear bearing (transfer cover side).
5. Install the ring gear to ring gear shaft, and apply anti-corrosive oil onto thread and seats on the mounting bolts. Then tighten mounting bolts to the specified torque.
6. Install ring gear bearing inner race (transfer cover side) with drift (A) (commercial service tool).
caution
  • Never reuse ring gear bearing (transfer cover side).
  • Apply transfer oil to the ring gear bearing (transfer cover side).
7. Install the ring gear bearing inner race (transfer case side) to ring gear shaft with 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).
8. Install the ring gear shaft assembly to the transfer case.
cautionProtect transfer case oil seals beforehand from being damaged by the spline of ring gear shaft below method following.
(1) Apply multi-purpose grease to spline part indicated in the figure.
(2) Wrap piece of a suitable vinyl to spline part only indicated in the figure.
: Limit line of wrapping
cautionNever wrap sliding surfaces on oil seal.
noteA plastic bag can be used by cutting it to fit.
9. 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.
10. 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.
11. Reinstall transfer cover to install O-ring. Refer to Disassembly and Assembly.
12. After installing transfer case oil seals, remove wrapped vinyl from the spline of ring gear shaft.