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TF-138
TRANSFER CONTROL DEVICE
Revision: October 20052005 QX56
TRANSFER CONTROL DEVICEPFP:33251
Removal and InstallationEDS0 02 IW
Refer to the figure for transfer control device removal and installation information.
CAUTION:
Change vehicle state to 2WD or AUTO, and then remove and install transfer control device.
Check 4WD shift indicator after installation. Refer to TF-4, "Precautions for Transfer Assembly and
Transfer Control Unit Replacement" .
1. Shift lever 2. Actuator
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AIR BREATHER HOSE
TF-139
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Revision: October 20052005 QX56
AIR BREATHER HOSEPFP:31098
Removal and InstallationEDS002IX
Refer to the figure for air breather hose removal and installation information.
CAUTION:
Make sure there are no pinched or restricted areas on the air breather hose caused by bending or
winding when installing it.
Install the air breather hose into the air breather (metal connector) and actuator (case connector)
until the hose end reaches the base of the tube.
Install the air breather hose into the breather tube (metal connector) and transfer motor (case con-
nector) until the hose end reaches the end of the curved section.
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TF-140
TRANSFER MOTOR
Revision: October 20052005 QX56
TRANSFER MOTORPFP:00000
Removal and InstallationEDS002IY
REMOVAL
1. Disconnect the transfer motor connector.
2. Remove the air breather hose from the transfer motor. Refer to
TF-139, "
Removal and Installation" .
3. Remove the transfer motor bolts.
4. Remove the transfer motor.
INSTALLATION
1. Apply ATF to the O-ring and install it to the transfer motor.
CAUTION:
Do not reuse O-rings.
2. Fit the double-flat end of the transfer motor shaft into the slot of
the sub-oil pump assembly. Then tighten to the specified torque.
Refer to TF-144, "
COMPONENTS" .
CAUTION:
Be sure to install connector bracket.
3. Install the air breather hose to the transfer motor. Refer to TF-
139, "Removal and Installation" .
4. Connect the transfer motor connector.
5. Check the transfer fluid. Refer to MA-25, "
FLUID LEAKAGE AND FLUID LEVEL" .
6. Start the engine for one minute. Then stop the engine and recheck the transfer fluid. Refer to MA-25,
"FLUID LEAKAGE AND FLUID LEVEL" .
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TRANSFER OIL FILTER
TF-141
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TRANSFER OIL FILTERPFP:00000
Removal and InstallationEDS0 02 IZ
REMOVAL
1. Remove the oil filter bolts and oil filter.
CAUTION:
Do not damage center case and oil filter.
Loosen bolts and detach oil filter evenly.
2. Remove the O-rings from the oil filter.
3. Remove the oil filter stud from the oil filter.
4. Remove the O-ring from the oil filter stud.
INSTALLATION
1. Apply ATF to the O-ring, and install it on the oil filter stud.
CAUTION:
Do not reuse O-ring.
2. Install the oil filter stud to the oil filter.
SMT875C
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TF-142
TRANSFER OIL FILTER
Revision: October 20052005 QX56
3. Apply ATF to the two O-rings (1), and install them on the oil filter
(2).
CAUTION:
Do not reuse O-rings.
4. Install the oil filter to the transfer assembly. Tighten the bolts to
the specified torque. Refer to TF-144, "
COMPONENTS" .
CAUTION:
Do not damage oil filter.
Attach oil filter and tighten bolts evenly.
5. Check the transfer fluid. Refer to MA-25, "
FLUID LEAKAGE
AND FLUID LEVEL" .
6. Start the engine for one minute. Then stop the engine and
recheck the transfer fluid. Refer to MA-25, "
FLUID LEAKAGE
AND FLUID LEVEL" .
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TRANSFER ASSEMBLY
TF-143
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Revision: October 20052005 QX56
TRANSFER ASSEMBLYPFP:33100
Removal and InstallationEDS0 02 H1
REMOVAL
1. Remove the drain plug and gasket. Drain the fluid. Refer to MA-24, "DRAINING" .
2. Remove the A/T undercover, using power tool.
3. Remove the center exhaust tube and main muffler. Refer to EX-3, "
Removal and Installation" .
4. Remove the front and rear propeller shafts. Refer to PR-4, "
Removal and Installation" (front), PR-8,
"Removal and Installation" (rear).
CAUTION:
Do not damage spline, sleeve yoke and rear oil seal when removing rear propeller shaft.
NOTE:
Insert a plug into the rear oil seal after removing the rear propeller shaft.
5. Remove the A/T nuts from the A/T crossmember.
6. Position two suitable jacks under the A/T and transfer assembly.
7. Remove the crossmember. Refer to AT-247, "
COMPONENTS" .
WAR NIN G:
Support A/T and transfer assembly using two suitable jacks while removing crossmember.
8. Disconnect the electrical connectors from the following:
ATP switch
Neutral 4LO switch
Wait detection switch
Transfer motor
Transfer control device
9. Disconnect the air breather hoses from the following:
Transfer control device
Transfer rear case
Transfer motor
10. Remove the transfer control device from the extension housing.
11. Remove the transfer to A/T and A/T to transfer bolts.
WAR NIN G:
Support transfer assembly with suitable jack while removing it.
12. Remove the transfer assembly.
INSTALLATION
Installation is in the reverse order of removal, paying attention to the following:
Tighten the bolts to specification.
Fill the transfer with new fluid. Refer to MA-25, "FILLING" .
Check the transfer fluid. Refer to MA-25, "FLUID LEAKAGE
AND FLUID LEVEL" .
Start the engine for one minute. Then stop the engine and
recheck the transfer fluid. Refer to MA-25, "
FLUID LEAKAGE
AND FLUID LEVEL" . Bolt length : 45 mm (1.77 in)
Transfer bolt torque : 36 N·m (3.7 kg-m, 26 ft-lb)SMT872C
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TF-144
TRANSFER ASSEMBLY
Revision: October 20052005 QX56
Disassembly and AssemblyEDS002H2
COMPONENTS
1. 2-4 sleeve 2. L-H sleeve 3. Snap ring
4. Internal gear 5. Planetary carrier assembly 6. Metal bushing
7. Needle bearing 8. Sun gear 9. Carrier bearing
10. Snap ring 11. Snap ring 12. Mainshaft front bearing
13. Wait detection switch 14. Check plug 15. Check spring
16. Check ball 17. Front case 18. Snap ring
19. Oil seal 20. Shift cross 21. Oil seal
22. Lock pin 23. Shift lever 24. Gasket
25. Drain plug 26. Oil seal 27. Companion flange
28. Self-lock nut 29. Main shaft 30. Needle bearing
31. Front bearing 32. Front drive shaft 33. Rear bearing
34. Spacer 35. Drive chain 36. Clutch drum
37. Snap ring 38. Clutch hub 39. Snap ring
40. Retaining plate 41. Driven plate (10 sheet) 42. Drive plate (10 sheet)
43. Return spring assembly 44. Press flange 45. Thrust needle bearing
46. Snap ring 47. Retaining pin 48. L-H fork
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TRANSFER ASSEMBLY
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Revision: October 20052005 QX56
49. 2-4 fork 50. Shift fork spring 51. Fork guide
52. Retainer pin 53. Shift rod
1. Dust cover 2. Oil seal 3. Rear case
4. Air breather 5. Seal ring 6. Main oil pump cover
7. Inner gear 8. Outer gear 9. Main oil pump housing
10. D-ring 11. D-ring 12. Clutch piston
13. Thrust needle bearing race 14. Oil strainer 15. O-ring
16. Snap ring 17. Control valve assembly 18. Lip seal (7 pieces)
19. Gasket 20. Filler plug 21. Oil filter stud
22. O-ring 23. Oil filter 24. ATP switch
25 Neutral-4LO switch 26. Oil pressure check plug 27. Harness bracket
28. Stem bleeder 29. Harness bracket 30. Center case
31. Mainshaft rear bearing 32. C-ring 33. Washer holder
34. Snap ring 35. Sub oil pump housing 36. Outer gear
37. Inner gear 38. Sub oil pump cover 39. O-ring
40. Transfer motor 41. Connector bracket
WDIA0195E