Page 2129 of 2389

(c) Adjust the total preload by tightening the bearing adjusting
nut.
Using SST, tightening the adjusting nut.
SST 09318±20010
HINT: Measure the preload while tightening the adjusting nut
a little at a time.
(d) Using SST and a spring tension gauge, measure the total
preload.
SST 09326±20011
(Preload at starting):
New bearing
Add driven pinion preload
1.3± 1.4 kg (2.9±3.1 Ib, 12.7± 13.7 N)
Reused bearing
Add driven pinion preload
0.5±0.9kg (1.1 ±2.0Ib,4.9±8.8 N)
HINT: Turn the output shaft counterclockwise and clockwise
several times.
(e) When the standard value for total preload is exceeded, re-
move the transfer right case, push in the adjusting nut and
outer race.
Again adjust the total preload.
3. CHECK RING GEAR BACKLASH
(a) Using a dial indicator, measure the ring gear backlash.
Backlash: 0.13 ± 0.18 mm (0.0051 ± 0.0071 in.)
(b) When the backlash is outside the standard value, select a
different plate washer to the one selected step 2. Again
adjust the backlash and total preload. 2. ADJUST TOTAL PRELOAD
(a) Install the transfer right case.
(b) Install and torque the twelve bolts.
Torque: 450 kg±cm (33 ft±lb, 44 N±m)
HINT: The backlash will change about 0.02 mm (0.0008
in.) with each shim thickness.
Thickness mm (in.) Thickness mm (in.)
Mark
Mark
± MANUAL TRANSAXLEComponent Parts (Transfer Assembly E56F5)MT±184
Page 2130 of 2389
4. CHECK TOOTH CONTACT
(a) Coat 3 or 4 teeth at four different position on the ring
gear with red lead.
(b) Rotate the ring gear, inspect the teeth pattern.
5. REMOVE RING GEAR MOUNTING CASE ASSEMBLY
(a) Remove the twelve bolts and transfer right case.(e) If the teeth are not contacting properly, again se-
lect the proper shim and plate.
Thickness mm (in.)
Thickness mm (in.)
Mark
Mark
± MANUAL TRANSAXLEComponent Parts (Transfer Assembly E56F5)MT±185
Page 2131 of 2389
9. INSTALL TRANSFER RIGHT CASE
(a) Remove any packing material and be careful not to drop oil
on the contacting surfaces of the transfer left case or right
case.
(b) Apply seal packing to the transfer left case as shown in the
figure.
Seal packing: Part No.08826±00090, THREE BOND
1281 or equivalent
HINT: Install the transfer right case as soon as the seal pack-
ing is applied. 7. INSTALL DRIVEN PINION BEARING CAGE
ASSEMBLY
(a) Coat the O±ring with gear oil.
(b) Install the O±ring to the driven pinion bearing cage.
(c) Install the driven pinion bearing cage with adjust shim
(Previously selected) to the transfer left case.
(d) Install and torque the six bolts.
Torque: 400 kg±cm (29 ft±Ib. 39 N±m)
6. REMOVE DRIVEN PINION BEARING CAGE
ASSEMBLY
(a) Remove the six bolts and bearing cage assembly.
8. INSTALL RING GEAR MOUNTING CASE ASSEMBLY(b) Remove the ring gear mounting case assembly.
± MANUAL TRANSAXLEComponent Parts (Transfer Assembly F56 F5)MT±186
Page 2132 of 2389

14. INSTALL TRANSFER INSPECTION HOLE COVER
(a) Remove any packing material and be careful not to
drop oil on the contacting surfaces of transfer left
case or transfer inspection hole cover.
(b) Apply seal packing to the transfer left case as shown
in the figure.
Seal packing: Part No.08826±00090, THREE
BOND
1281 or equivalent
HINT: Install the transfer inspection hole cover as soon
as the seal packing is applied.(c) Apply sealant to the bolt threads.
Sealant: Part No.08833±00080, THREE BOND 1344,
LOCTITE 242 OR EQUIVALENT
(d) Install and torque the twelve bolts.
Torque: 450 kg±cm (33 ft±lb, 44 N±m)
10. CHECK TOTAL PRELOAD
(See page MT± 184)
11. INSTALL ADJUSTING NUT LOCK PLATE
Using snap ring pliers, install the lock plate so that the
projection from the lock plate fits properly into the
groove of the adjusting nut.
HINT: Choose one of the two types of lock plate can be
installed, tighten the adjusting nut to the minimum limit.
12. INSTALL SIDE GEAR SHAFT SIDE GEAR SHAFT
HOLDER
(a) Install the side gear shaft holder to the transfer right
case.
(b) Using snap ring pliers, install the snap ring.
13. INSTALL OIL SEAL
(a) Coat the lip of the oil seal with MP grease.
(b) Using a brass bar and hammer, drive in a new oil seal.
± MANUAL TRANSAXLEComponent Parts (Transfer Assembly E56F5)MT±187
Page 2133 of 2389
15. INSTALL EXTENSION HOUSING
(a) Coat the O±ring with gear oil.
(b) Install the O±ring to the extension housing.
(c) Install the extension housing to the driven pinion bear-
ing cage.
(e) Install and torque the four bolts.
Torque: 260kg±cm (19 ft±Ib, 25 N±m)
17. INSTALL DIFFERENTIAL LOCK SHIFT FORK
SHAFT
(a) Install the differential lock sleeve with shift fork.
(b) Install and torque the set bolt.
Torque: 160 kg±cm (12 ft±Ib, 16 N±m)
16. INSTALL DYNAMIC DANPER
Install and torque the four bolts.
Torque: 260 kg±cm (19 ft±Ib, 25 N±m)
(c) Using SST, install and torque the plug.
SST 09043±36100
Torque: 400 kg±cm (29 ft±Ib, 39 N±m)
(c) Install and torque the three bolts.
Torque: 160 kg±cm (12 ft±Ib, 16 N±M)
± MANUAL TRANSAXLEComponent Parts (Transfer Assembly E56F5)MT±188
Page 2134 of 2389
19. INSTALL TRANSFER VACUUM ACTUATOR
(a) Install the vacuum actuator.
(b) Install and torque the three bolts.(d) Install and torque the indicator switch.
Torque: 400 kg±cm (29 ft±Ib, 39 N±m)
(e) Using SST, install and torque the plug.
SST 09313±30021
Torque: 250 kg±cm (18 ft±Ib, 25 N±m)
(c) Install the stiffener center plate and actuator
bracket.
(d) Install and torque the four bolts.
Torque: 380 kg±cm (27 ft±lb, 37 N±m)
(e) Set the shift fork shaft at the as shown in the figure.
1s. INSTALL DUST BOOT
± MANUAL TRANSAXLEComponent Parts (Transfer Assembly)MT±189
Page 2135 of 2389
PROPELLER SHAFT
PROPELLER SHAFTPR±1
Page 2136 of 2389
Propeller and intermediate shafts runout
Propeller shafts imbalance
Front flange runout
Rear flange runout
Cross groove joint stuck or damaged
Transfer extension housing rear
bushing worn
Sleeve yoke spline stuck
PRECAUTION
Be careful not to grip the propeller shaft tube too tightly in
the vise as this will cause deformation.
Replace shafts
Balance propeller shafts
Replace front flange
Replace rear flange
Replace cross groove joint Replace sleeve yoke
Replace center support bearing
Replace propeller shafts Sleeve yoke spline worn
Center support bearing worn
Spider bearing worn or stuck
TROUBLESHOOTING
Replace sleeve yokePR±4
PR±4
PR±4
PR±7
PR±6
PR±8 Possible cause
VibrationProblemRemedy
NoisePage
PR±4
PR±4
± PROPELLER SHAFTPrecautionPR±2