Page 609 of 2100
4D2±26
TRANSFER CASE (TOD)
8. Remove the snap ring before the ring gear.
261RW025
9. Using the ring gear remover J±42806 and a bench
press, remove the ring gear from the transfer case.
261R200005
NOTE: Removing ring gear needs a high-load press.
This means the transfer case may be damaged.
To remove and replace the ring gear, it is recommended
that the transfer case assembly should be replaced.10. Remove the ball bearing of the front output shaft from
the transfer case.
261RY00021
Reassembly
Oil Seal Replacement
1. Remove the oil seal of the front output shaft and input
shaft from the transfer case.
2. Apply the circumference of the new oil seal and fill the
lip with grease (BESCO L2 or its equivalent).
3. Using the oil seal installer J±42807, install the front
output shaft oil seal to the transfer case.
266RY00013
Page 610 of 2100

4D2±27 TRANSFER CASE (TOD)
4. Using the oil seal installer J±42808, install the input
shaft oil seal to the transfer case.
261RY00031
5. Using the ring gear installer J±42809 and a bench
press, install the ring gear to the transfer case.
NOTE: 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.
261R200007
6. Install the snap ring.
7. Install the thrust plate to the carrier assembly.
Attach the snap ring to the carrier assembly.
8. Install the carrier assembly to the input shaft.
9. With care the direction of circular hub, mount it to the
input shaft.
265RW008
10. Press the ball bearing to the input shaft so that the
snap ring will be attached to the input shaft.
265RY00004
11. Install the snap ring to the input shaft.
12. Install the ball bearing of the front output shaft to the
transfer case.
Page 611 of 2100

4D2±28
TRANSFER CASE (TOD)
13. Install the snap ring of the input shaft bearing to the
transfer case.
265RY00003
14. Using snap ring pliers, open the snap ring from the
gap on the carrier assembly.
While opening the snap ring, securely attach the input
shaft and carrier assembly to the transfer case.
265RY00002
Inspection and Repair (Transfer Case
Assembly)
When wear, damage, or any other defects are observed
during the inspection, the part or parts must be repaired or
replaced. Wash all the parts with clean detergent, and
check that old oil, metallic particles, dirt, or foreign
materials are completely removed. Blow the air into oil
holes and grooves to remove foreign materials or residual
detergent.
Chain
Check whether the face that contacts the sprocket is
free from excessive wear or damage. If defects are
observed, replace the part.
If the chain interference mark is found on the inside
wall of the transfer cover or the chain is so slack that a
skipped engagement occurs between the chain and
sprocket, replace the chain.
Sprocket
Check whether the sprocket tooth surface is
excessively worn or damaged, and there is evidence
of burrs, chipping, wear, or damage on the gear
spline. Remove minor flaws or scratches with oil
stone. If excessive wear or damage is observed,
replace the part.
If excessive wear or damage is observed on the
sprocket inside sliding surface, replace the part.
Gear
Check whether the gear tooth surface is excessively
worn or damaged, and there is evidence of burrs,
chipping, wear, or damage on the gear spline.
Remove minor flaws or scratches with oil stone. If
excessive wear or damage is observed, replace the
part.
Thickness of Reduction Hub
Measure the thickness with a micrometer.
If the measurement exceeds the limit, replace the
reduction hub.
Standard : 3.05±3.30 mm (0.120±0.130 in)
Allowable limit : 2.5 mm (0.098 in)
265RW005
Page 612 of 2100

4D2±29 TRANSFER CASE (TOD)
Lockup Collar Assembly
Install the lockup hub, drive sprocket assembly, and
lockup collar assembly to the output shaft.
If the lockup collar assembly does not move
smoothly, replace the lockup collar assembly.
NOTE: Apply ATF to the rear engaging the gear.
Width of Lockup Collar
Using calipers, measure the lockup collar groove for
width of wear.
If the measurement exceeds the limit, replace the
lockup collar assembly.
Standard : 7.16±7.32 mm (0.282±0.288 in)
Allowable limit : 7.9 mm (0.311 in)
262RY00018
Shift Fork and Rail Assembly
Check the shift fork and rail for wear, distortion, and
scratches. If defects are observed, replace the parts.
Thickness of Shift Fork
If the measurement exceeds the limit, replace the
shift fork.
Standard : 3.41±3.79 mm (0.134±0.149 in)
Allowable limit : 4.4 mm (0.173 in)
262RY00016
Lockup Fork and Rail
Check the lockup fork and rail for wear, distortion, and
scratches. If defects are observed, replace the parts.
Thickness Lockup Fork
If the measurement exceeds the limit, replace the lockup
fork.
Standard : 6.99±7.09 mm (0.275±0.279 in)
Allowable limit : 6.3 mm (0.248 in)
262RY00017
Page 613 of 2100

4D2±30
TRANSFER CASE (TOD)
Bearing
Check the profile of the needle, roller, ball, and thrust
bearings. Wash the bearings with clean detergent
completely, and dry with air.
NOTE: If the bearing is rotated excessively, the rollers
may be damaged. So, rotate the bearing slowly with your
hand. Apply grease to the bearing, and check the
smoothness of the bearing while slowly rotating the race
with your hand.
Allowable limit : 0.23 mm (0.009 in)
226RW143
Lockup Fork Spring
Check the lockup fork spring for distortion, cracking, and
wear. If defects are observed, replace the part.
Multi Plate Disk Clutch
If the burned, mirror-surfaced clutch facing, or
scraping is observed on the clutch plates, clutch
housing, armature plate, and insulator washer,
replace the parts.
266R200003
Legend
(1) Clutch Housing
(2) Clutch Plate
(3) Insulator Washer
(4) Armature Plate
Coil Assembly
Check the resistance of the coil with a tester. If
defects are observed, replace the coil assembly.
Standard : 1.7+0.3 (at ordinary temperature)
Allowable limit : 1.0~5.0
261RY00022
Cam Pulley, Cam Ball, and Cam & Coil
Housing
Check the cam balls and cam for excessive wear or
damage. If defective, replace the parts.
266RW016
Page 614 of 2100
4D2±31 TRANSFER CASE (TOD)
4H and 4L Switch
Check the continuity of 4H and 4L switch.
If defects are observed, replace the 4H and 4L switch.
261R200006
261RW049
Switch
Stroke4H Switch
Signal4L Switch
SignalThe
correspon-
ding
Terminal 2 to
Switch BodyTerminal
1 to 3
g
position of
TOD
switch
1OpenOpen2H, TOD
2OpenClose4L
3CloseCloseNeutral
Shift Motor Assembly
Check the resistance of the shift motor assembly
(between terminal 4 to 7) with a tester.
If defects are observed, replace the shift motor
assembly.
Standard : 0.63+0.2 (at ordinary temperature)
8±6
261RY00023
Oil Pump
Remove foreign materials from the strainer. If the
strainer is damaged, replace it.
If the area into which the shaft is inserted is
excessively worn or damaged, replace the oil pump
assembly.
Page 615 of 2100
4D2±32
TRANSFER CASE (TOD)
Main Data and Specification
General Specification
TypeElectronically controlled torque split four wheel drive with two wheel
drive.
2WD: Rear two wheel drive
TOD: Electronically controlled torque split four wheel drive.
4L: Low speed mechanical lockup four wheel drive.
Rear drive: Direct drive
Front drive: Chain drive
Low range deceleration: Planetary gear drive
Control systemSwitch control
Gear ratioHigh: 1.000
Low: 2.480
Lubrication systemBuilt-in oil pump
Forced lubrication
Type of lubricantATF DEXRON)±II or III
Oil capacity1.35 liters. (1.43 US.quart)
Clutch discs number13
Planetary gear teeth numberSun gear: 58
Pinion gear: 15
Ring gear: 86
Page 616 of 2100
4D2±33 TRANSFER CASE (TOD)
Torque Specifications
E04R200001