Page 4337 of 6000
4D2–30
TRANSFER CASE (TOD)
Transfer Case
Disassembled View
265RW015
Legend
(1) Transfer Case
(2) Ball Bearing
(3) Ring Gear
(4) Snap Ring
(5) Input Shaft and Carrier Assembly
(6) Snap Ring(7) Ball Bearing
(8) Snap Ring
(9) Thrust Plate
(10) Carrier Assembly
(11) Snap Ring
(12) Circular Hub
(13) Input Shaft
Reassembly
1. Remove the oil seal from the transfer case.
2. Apply engine oil to the circumference of the new oil
seal and fill the lip with grease (Besco L2 or
equivalent).
Page 4338 of 6000
4D2–31 TRANSFER CASE (TOD)
3. Using the front output shaft oil seal installer
5-8840-2410-0 (J-42807), install the oil seal to the
transfer case.
261RW053
Front Output Shaft Oil Seal
Distance between the transfer case end and oil seal.
NOTE: When installing the oil seal to the specified
dimension, be careful not to damage it.
Distance : 0.93 — 1.43mm (0.037 — 0.056 in)
A04RW003
4. Using the input shaft (main) oil seal installer
5-8840-2411-0 (J-42808), install the oil seal to the
transfer case.
261RW055
Input Shaft Oil Seal
Distance between the transfer case end and oil seal.
NOTE: When installing the oil seal to the specified
dimension, be careful not to damage it.
Distance : 3.25 — 3.75mm (0.13 — 0.15 in)
A04RW002
Page 4339 of 6000
4D2–32
TRANSFER CASE (TOD)
5. Using the installer 5-8840-2416-0 (J-42809), press-fit
the ring gear.
Pay attention to the following points.
Identify the correct direction of gear.
Do not damage the gear.
Do not press-fit the ring gear slantingly.
Press-fit the ring gear to the innermost.
Remove burrs generated by press-fitting.
If the transfer case has serrations, match them with
those of the gear and press-fit the gear.
261RW054
261RW034
6. Install the snap ring to the transfer case.
7. Install the circular hub.
8. Install the snap ring to the carrier.
9. Mount the carrier assembly to the input shaft.
10. Check the direction of thrust plate and mount it to the
input shaft.
265RW008
11. Mount the ball bearing to the input shaft so that the
snap ring will be installed to the input shaft.
265RW003
12. Install the snap ring to the input shaft.
13. Install the snap ring to the transfer case.
Page 4340 of 6000
4D2–33 TRANSFER CASE (TOD)
14. Using the snap ring pliers, expand the snap ring
through the opening between the ring gear and carrier
assembly and securely install the input shaft and
carrier assembly.
261RW038
15. Install the ball bearing (for front output shaft)
Page 4341 of 6000
4D2–34
TRANSFER CASE (TOD)
Output Shafts and Shift Control Shaft
Disassembled View
261RW010–1
Legend
(1) Transfer Case Assembly
(2) Detent Spring
(3) Front Output Shaft
(4) Reduction Hub
(5) Output Shaft
(6) Reduction Fork Assembly
(7) Lock-up Shaft
(8) Spring Pin
(9) Reduction Fork(10) Cam Assembly
(11) Snap Ring
(12) Washer
(13) Cam
(14) Cam Pilot Block
(15) Shifter Shaft Assembly
(16) Shifter Lever Shaft
(17) Snap Ring
(18) Reduction Lever Assembly
(19) Snap Ring
Reassembly
1. Apply ATF to the inside of the ball bearing for the front
output shaft.
Page 4342 of 6000
4D2–35 TRANSFER CASE (TOD)
2. Mount the front output shaft to the transfer case.
266RW012
3. Install the shifter lever shaft to the transfer case
assembly.
4. Install the snap ring to the shifter lever shaft.
5. Install the reduction lever assembly to the shifter lever
shaft and fix the assembly with the snap ring.
261RW021
6. Install the cam to the cam pilot block.
7. Attach the washer to the cam pilot block and fix the
washer with the snap ring.
261RW029
8. Mount the reduction fork to the lock-up shaft.
9. Install the spring pin to the reduction fork and lock-up
shaft.
261RW020
Page 4343 of 6000
4D2–36
TRANSFER CASE (TOD)
10. Install the reduction fork assembly together with
reduction hub to the transfer case assembly.
261RW019
11. Install the cam assembly and tighten the cam pilot
block set bolts to the specified torque.
Torque : 12 Nꞏm (1.2 kgꞏm/104 lb in)
12. Tighten the detent spring to the specified torque.
Torque : 24 Nꞏm (2.4 kgꞏm/17 lb in)
261RW022
13. Apply ATF to the needle bearing inside the input shaft
assembly.
14. Install the output shaft to the transfer case assembly.
Page 4344 of 6000
4D2–37 TRANSFER CASE (TOD)
Sprocket and Mechanical Lock
Disassembled View
266RW008
Legend
(1) Strainer
(2) Hose
(3) Oil Pump Assembly
(4) Thrust Washer
(5) Mechanical Lock Hub
(6) Lock-up Sleeve(7) Lock-up Fork
(8) Chain
(9) Lower Drive Sprocket
(10) Front Tone Wheel
(11) Drive Sprocket
(12) Sprocket Spacer
Reassembly
1. Connect the hose and strainer to the oil pump
assembly.
2. Install the oil pump assembly to the output shaft and
set the magnet to the strainer position.
3. Install the thrust washer.
4. Install the spring to the lock-up fork.