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TRANSFER ASSEMBLY
TF-15
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5. If tooth contact is poorly adjusted, adjust pinion height (dimen-
sion X) in the following manner:
SDIA0520E
SDIA0517E
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TF-16
TRANSFER ASSEMBLY
●If the tooth contact is near the face (face contact), or near the
heal (heal contact), thin the pinion sleeve shims to move the
drive pinion gear closer to the drive gear.
●If the tooth contact is near the flank (flank contact), or near the
toe (toe contact), thicken the pinion sleeve shims to move the
drive pinion gear farther from the drive gear.
PRELOAD TORQUE
Pinion bearing preload torque
1. Remove the pinion sleeve assembly, and rotate the companion flange back and forth in 2 to 3 times.
Check for abnormal noise, rotation malfunction, and other malfunctions.
2. Rotate the companion flange at least 20 times to check for smooth operation of the bearing.
SDIA0518E
SDIA0519E
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TRANSFER ASSEMBLY
TF-17
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3. Using a preload gauge, measure the preload torque of the pin-
ion bearing.
CAUTION:
Every rotational part shall rotate smoothly with the speci-
fied gear oil.
●If outside the standard, disassemble the pinion sleeve assem-
bly to check and adjust each part.
Overall preload torque
1. Measure pinion bearing preload torque (P1 ).
2. Install the pinion sleeve shims and pinion sleeve assembly.
3. Rotate the companion flange at least 20 times to check for smooth operation of the bearing.
4. Using a preload gauge, measure the overall preload torque.
●If outside of the standard, disassemble it to check and adjust
each part. If measuring the overall preload torque after the disassembly, measure it with the transfer
case oil seals and gear ring oil seals removed, then install the oil seals.
COMPANION FLANGE RUNOUT
1. Fit a dial gauge onto the companion flange face (inner side of
the propeller shaft mounting bolt holes).
2. Rotate the companion flange to check for runout.
3. Fit a test indicator to the inner side of the companion flange
(socket diameter).
4. Rotate the companion flange to check for runout.
5. If the runout value is outside the repair limit, follow the procedure
below to adjust.
a. While changing the phase between companion flange and drive pinion gear by 90° at a time, check runout
and determine which phase angle minimizes the runout.
b. If the runout value is still outside of the limit after the phase has been changed, replace the companion
flange.
c. If the runout is outside the standard after the companion flange is replaced, adjust the assembly status of
the pinion bearings and drive pinion gear, or replace the pinion bearings. Preload torque
: 0.10 - 0.39 N·m (0.01 - 0.04 kg-m,1 - 3 in-lb)
SDIA0522E
Pinion bearing preload torque (P1)
: 0.10 - 0.39 N·m (0.01 - 0.04 kg-m, 1 - 3 in-lb)
Overall preload torque
When all oil seals are installed:
: P
1 +0.16 - 0.22 N·m (0.016 - 0.023 kg-m, 1.4 - 1.9
in-lb)
Transfer case oil seals and
When no gear ring oil seal:
: P
1 +0.06 - 0.12 N·m (0.006 - 0.013 kg-m, 0.6 - 1.1
in-lb)
SDIA0523E
Runout limit : 0.08 mm (0.0031 in)
Runout limit : 0.08 mm (0.0031 in)
SDIA0524E
Page 2628 of 3833
TF-18
TRANSFER ASSEMBLY
Disassembly and Assembly
EDS0004X
DISASSEMBLY
Pinion sleeve assembly
1. Remove 7 pinion sleeve mounting bolts.
2. Temporarily tighten 2 bolts. Using a plastic hammer, tap com-
panion flange to remove pinion sleeve assembly.
3. Remove the pinion sleeve shim.
4. Remove the pinion nut.
5. Using a drift, remove drive pinion from pinion sleeve with a
press.
6. Remove the drive pinion gear assembly.
7. Remove the O-ring.
8. Using a flat-bladed screwdriver, remove the oil seal.
CAUTION:
Be careful not to damage the pinion sleeve.
9. Remove the pinion rear bearing inner race.
TFB0302D
TFB0284D
SDIA0525E
TFB0286D
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TRANSFER ASSEMBLY
TF-19
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10. Using a puller, remove the pinion rear bearing outer race.
11. Using a puller, remove the pinion front bearing outer race.
12. Remove the collapsible spacer from the drive pinion gear.
13. Using a replacer, press the pinion front bearing inner race out of
the drive pinion gear.
Adapter case
1. Remove the adapter case mounting bolts.
SDIA0526E
SDIA0527E
SDIA0528E
TFB0289D
Page 2630 of 3833
TF-20
TRANSFER ASSEMBLY
2. Using a plastic hammer, tap the adapter case to remove.
3. Remove the O-ring.
4. Using a flat-bladed screwdriver, remove the oil seal.
CAUTION:
Be careful not to damage the adapter case.
5. Using a brass rod, tap the adjusting shim from the cutout on the
adapter case to remove the adjusting shim and gear ring bear-
ing outer race.
6. Remove the oil gutter.
7. Remove the drain plug.
Drive gear assembly
1. Remove the adapter case.
2. Remove the drive gear assembly from the transfer case.
TFB0290D
TFB0291D
SDIA0529E
SDIA0530E
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TRANSFER ASSEMBLY
TF-21
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3. Using a drift and replacer, remove the gear ring bearing inner
race on the adapter case.
4. Using a drift and puller, remove the gear ring bearing inner race
on the transfer case.
5. Remove the drive gear mounting bolts.
6. Using a plastic hammer, tap the drive gear to remove the drive
gear from the gear ring.
7. Using a puller, remove the oil seal from the gear ring.
Transfer case
1. Remove the pinion sleeve assembly.
2. Remove the adapter case.
3. Remove the drive gear assembly from the transfer case.
SDIA0531E
SDIA1157E
TFB0295D
SDIA0534E
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TF-22
TRANSFER ASSEMBLY
4. Using a flat-bladed screwdriver, remove the oil seal.
CAUTION:
Be careful not to damage the transfer case.
5. Remove the oil defense.
6. Using a brass rod, tap the adjusting shim evenly from the 2 cut-
outs on the transfer case to remove the adjusting shim and gear
ring bearing outer race.
7. Remove the filler plug, and breather tube.
INSPECTION AFTER DISASSEMBLY
Gears
●Check the gear faces and shaft for wear, cracks, damage, and seizure.
CAUTION:
If a malfunction is detected on the drive gear or drive pinion gear, replace the drive gear and drive pin-
ion gear as a set.
Bearings
●Check for seizure, peeling, wear, corrosion, sticking/abnormal noise/roughness in hand turning, and other
damage.
CAUTION:
When replacing the bearing, always replace the inner race and outer race as a pair.
Washers and shims
●Check for seizure, damage, and abnormal wear.
Oil seals
●Discard old oil seals; replace with new ones.
●If wear, deterioration of adherence (sealing force of lips), or damage is detected on the lips, replace them.
TFB0297D
SDIA0535E
SDIA0536E