Page 961 of 2103
MANUAL TRANSAXLE OVERHAUL
(both sides)
SEALANT APPLICATION TO COVER
Specified sealant:
A T D P a r t or .
TOOTH CONTACT PROCEDURES
1. Standard tooth contact pattern
A. . . .Small end side
. . . .Drive side tooth face
(Side on which force acts running forward)
. . . .Big end side
. . . .Coast side tooth face(Side on which force acts when reversing)
2.Tooth contact pattern, produced when drive gear
height is too large
Cause
The driven bevel is too close to the drive bevei ge ar.
Remedy
Use thicker bevel gear mount adjusting spacer to se parate
the driven bevel gear more from the drive bevel gear.
3. Tooth contact pattern produced when driven bevel gear height is too small
Cause
The driven bevel, gear is too separated from the dr ive
bevel gear.
Page 962 of 2103

MANUAL TRANSAXLE OVERHAUL Transfer
Drive bevel gear
mount adjusting
spacerDrive bevel gearpreload adjusting
‘ D r i v e nbevelgearmountadjusting
spacer
Driven
bevel gear
preload
adjusting
spacer
22210129
R e m e d y
Use thinner driven bevel gear mount adjusting space r,
to briiig the driven bevel gear
closer to the drive
bevel gear.
NOTE . .
(1) If’ correct tooth contact cannot change of the driven
spacer, increase or decrease;
bevel gear preload adjusting,
bevel gear mount
and then adjust
lWhen the driven ‘bevel gear height is too small
if the thinnest driven bevel gear mount adjusting
spacer 0.13 mm in.) is used:
Replace the drive bevel gear mount adjusting spacer
that is in use with one rank thicker and
replace the drive bevel preload adjusting spacer th at
is in use with one that is ‘thinner.
l When the driven bevel too large even
if the thickest driven __
Replace the drive. bevel gear mount
that is in use with one that is
replace the drive bevel gear preload adjusting spacer
equal or close to the standard pattern
to the standard pattern by above adjustment, replac e
the drive bevel gear and as a set
, ,
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Page 963 of 2103
,,
, ,
DISASSEMBLY AND REASSEMBLY
Disassembly steps
1. Air bleeder2. Dust seal guard
3. Oii seal4. Extention housing
REASSEMBLY SERVICE POINTS
OIL SEAL INSTALLATION
AIR BLEEDER
Install the air bleeder
Specified sealant:
SUPER WEATHERSTRIP
,
Page 964 of 2103
MANUAL TRANSAXLE OVERHAUL
TRANSFER CASE
DISASSEMBLY AND REASSEMBLY . .
Nm29
Disassembly steps
1.Transfer cover
2.O-ring3.Spacer4.Outer race
5. Drive bevel gear assembly
6.Outer race7.Spacer 6. Oil seal9.Transfer case
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Page 965 of 2103
MANUAL TRANSAXLE OVERHAUL,.
Case“ , ,
I , ,
SPACER
(1) Use the existing spacer assemble the transfer case.
(2) Using the special
that the rotating
drive torque is within the standard value.
Standard value:
(3) If the rotating drive torque is outside of the stan dard value,
adjust using adjusting spacers.
NOTE
For adjustment, use two spacers of which thickness is
as close as possible to each other.
O-RING INSTALLATION .Caution
Apply transmission oil to
. . . ..
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Page 966 of 2103
MANUAL TRANSAXLE OVERHAUL ,
Transfer Case Adapter
TRANSFER CASE ADAPTER
DISASSEMBLY AND REASSEMBLY
8
Disassembly steps
1. Lock nut2. Driven bevel gear assembly
3. Taper roller bearing 4. Spacer
22210133
5. Collar6. Outer race
7. Outer race
6. Transfer case assembly
DISASSEMBLY SERVICE POINTS
LOCK NUT REMOVAL
(1) Unlock the lock nut. (Straighten the bent nut.)
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Page 967 of 2103
MANUAL TRANSAXLE OVERHAULTransfer Case Adapter
I I
2
4
I
(2) Holding gear, in vise
special tool, remove the lock nut.
REASSEMBLY POINTS
SPACER
(1) Use the exisfing spacer to assemble the transfer case
adapter.
(2) Using the special tool, check that the bevel gear rotating
drive torque is within standard value.
Standard value:
Nm
(3) If the rotating drive torque is outside of the stan dard value,
adjust using adjusting spacers.
TAPER ROLLER BEARING INSTALLATION
LOCK NUT INSTALLATION
(1) Holding the driven bevel gear in a vise and usi ng the
special tool, tighten the lock nut to specified torque.
(2) Caulk the lock nut at two positions.. .
Page 968 of 2103
MANUAL TRANSAXLE OVERHAULDrive .
DRIVE BEVEL GEAR
DISASSEMBLY AND REASSEMBLY
Disassembly steps
1. Taper roller bearing 2. Taper roller bearing 3. Drive bevel gear
4. Drive bevel gear shaft
22210142
DISASSEMBLY SERVICE POINTS‘.
ROLLER BEARING REMOVAL