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TF-162
TRANSFER ASSEMBLY
Revision: October 20052005 QX56
Planetary Carrier
Measure the end play of each pinion gear. If it is out of specifica-
tion, replace the planetary carrier assembly with a new one.
Check the working face of each gear and bearing for damage,
burrs, partial wear, dents and other abnormality. If any is found,
replace the planetary carrier assembly with a new one.
Sun Gear
Check if the oil passage of the sun gear assembly is clogged.
For this, try to pass a 3.6 mm (0.142 in) dia. pin through the oil
passage as shown.
Check the sliding and contact surface of each gear and bearing
for damage, burrs, partial wear, dents, and other abnormality. If
any is found, replace the sun gear assembly with a new one.
Internal Gear
Check the internal gear teeth for damage, partial wear, dents
and other abnormality. If any is found, replace the internal gear
with a new one.
Gears and Drive Chain
Check the gear faces and shaft for wear, cracks, damage, and
seizure.
Check the surfaces which contact the sun gear, clutch drum,
clutch hub, press flange, clutch piston and each bearing for
damage, peel, partial wear, dents, bending, or other abnormal
damage. If any is found, replace with a new one.Pinion gear end play : 0.1 - 0.7 mm (0.004 - 0.028 in)
PDIA0185E
PDIA0186E
SMT008D
SMT944C
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TRANSFER ASSEMBLY
TF-163
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Bearing
Make sure the bearings roll freely and are free from noise, pit-
ting and cracks.
Main Oil Pump
1. Check the inner and outer circumference, tooth face, and side-
face of the inner and outer gears for damage or abnormal wear.
2. Measure the side clearance between the main oil pump housing
edge and the inner and outer gears.
3. Make sure the side clearance is within specification. If the mea-
surement is out of specification, replace the inner and outer
gears with new ones as a set. Refer to TF-163, "
Main Oil Pump"
.
Sub-oil Pump
1. Check the inner and outer circumference, tooth face, and side-
face of the inner and outer gears for damage or abnormal wear.
2. Measure the side clearance between the sub oil pump housing
edge and the inner and outer gears.
3. Make sure the side clearance is within specification. If the mea-
surement is out of specification, replace the inner and outer
gears with new ones as a set. Refer to TF-163, "
Sub-oil Pump" .
Control Valve
Check resistance between the terminals of the clutch pressure
solenoid valve, 2-4WD shift solenoid valve, clutch pressure
switch and the transfer fluid temperature sensor. Refer to TF-90,
"COMPONENT INSPECTION" (clutch pressure solenoid
valve), TF-94, "
COMPONENT INSPECTION" (2-4WD solenoid
valve), TF-107, "
COMPONENT INSPECTION" (clutch pressure
switch) and TF-104, "
COMPONENT INSPECTION" (transfer
fluid temperature sensor).
SDIA2175E
Specification : 0.015 - 0.035 mm (0.0006 - 0.0014 in)
SDIA2174E
Specification : 0.015 - 0.035 mm (0.0006 - 0.0014 in)
SDIA2173E
WDIA0199E
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TF-164
TRANSFER ASSEMBLY
Revision: October 20052005 QX56
Check the sliding faces of the control valves and plugs for
abnormality. If any is found, replace the control valve assembly
with a new one. Refer to TF-182, "
Control Valve" .
CAUTION:
Replace control valve body together with clutch return
spring as a set.
Check each control valve spring for damage or distortion. Also
check its free length, outer diameter and wire diameter. If any
damage or fatigue is found, replace the control valve body with a
new one. Refer to TF-182, "
Control Valve Spring" .
CAUTION:
Replace control valve body together with clutch return
spring as a set.
Clutch
Check the drive plate facings and driven plate for damage,
cracks or other abnormality. If any abnormalities are found,
replace with a new one.
Check the thickness of the drive plate facings and driven plate.
Refer to TF-164, "
Clutch" .
CAUTION:
Measure facing thickness at 3 points to take an average.
Check all drive and driven plates.
Check return spring for damage or deformation.
Do not remove spring from plate.
Return Spring
Check the stamped mark shown. Then, check that the free
lengths, (include thickness of plate) are within specifications. If
any abnormality is found, replace with a new return spring
assembly of the same stamped number. Refer to TF-164,
"Return Spring" .
SMT947C
SMT948C
SMT949C
SDIA2176E
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TRANSFER ASSEMBLY
TF-165
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ASSEMBLY
Center Case
1. Apply ATF to the O-ring, and install it on the oil filter stud.
CAUTION:
Do not reuse O-rings.
2. Install the oil filter stud to the oil filter.
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 center case. 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. Install the outer gear and inner gear into the sub oil pump hous-
ing, and measure the side clearance. Refer to TF-163, "
Sub-oil
Pump" .
SDIA2784E
WDIA0285E
SDIA2136E
SDIA2135E
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TF-166
TRANSFER ASSEMBLY
Revision: October 20052005 QX56
6. Align the dowel pin hole and bolt hole of the sub oil pump
assembly with the center case. Install the sub oil pump cover.
Then tighten to the specified torque. Refer to TF-144, "
COMPO-
NENTS" .
7. Apply ATF to the O-ring and install it to the transfer motor.
CAUTION:
Do not reuse O-rings.
8. 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.
9. Assemble the control valve assembly with the following procedure.
CAUTION:
Do not reuse any part that has been dropped or damaged.
Make sure valve is assembled in the proper direction.
Do not use a magnet because residual magnetism stays during assembly.
Retainer plate (1)
Plug (2)
a. Clean the upper body (5), control valves (3) and springs (4) with
cleaning agent, and dry with compressed air.
b. Dip the control valves (3) in ATF, and apply ATF to the valve-
mounting area of the upper body (5).
c. Install each control valve, spring, and plug to the upper body,
and install retainer plates to hold them in place.
CAUTION:
To insert control valves into upper body, place upper
body on a level surface in order to prevent flaw or dam-
age.
Make sure each control valve is smoothly inserted.
SDIA2328E
SDIA2787E
WDIA0284E
SDIA2127E
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TRANSFER ASSEMBLY
TF-167
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d. Install the reverse balls, relief balls and relief springs, accumula-
tor pistons and valve springs to the upper body.
e. Install the lower body and separator plate to the upper body.
CAUTION:
Do not reuse separator plates.
f. With the lower body down, tighten the two bolts shown.
g. Apply ATF to the O-rings, and install them to each solenoid
valve, switch and terminal body.
CAUTION:
Do not reuse O-rings.
h. Install the following to the control valve assembly:
Clutch pressure solenoid valve
Clutch pressure switch
2-4WD shift solenoid valve
Line pressure switch
Transfer fluid temperature sensor
10. Apply ATF to lip seals, and install them to the center case.
CAUTION:
Do not reuse lip seals.
There are 2 kinds of lip seals (lip seal of large inner diam-
eter: 5 pieces, lip seal of small inner diameter: 2 pieces).
Confirm their position for installation.
SDIA2126E
WDIA0200E
WDIA0198E
SDIA2123E
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TF-168
TRANSFER ASSEMBLY
Revision: October 20052005 QX56
11. Install the control valve assembly to the center case, and tighten
to the specified torque. Refer to TF-144, "
COMPONENTS" .
CAUTION:
Do not reuse any part that has been dropped or damaged.
Make sure valve is assembled in the proper direction.
Do not use a magnet because residual magnetism stays
during assembly.
12. Install the connector assembly into the center case, and secure
with a snap ring.
13. Apply ATF to the O-rings, and install them on the oil strainer.
CAUTION:
Do not reuse O-rings.
14. Install the oil strainer to the control valve assembly.
15. Tighten the bolts to the specified torque. Refer to TF-144,
"COMPONENTS" .
16. Apply ATF to the D-rings, and install them to the clutch piston.
CAUTION:
Do not reuse D-rings.
SDIA2121E
SDIA2122E
SDIA2782E
SDIA2 119 E
SDIA2781E
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TRANSFER ASSEMBLY
TF-169
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17. Install the thrust needle bearing race to the clutch piston.
18. Install the clutch piston to the center case as shown.
CAUTION:
Install so the fitting protrusion of clutch piston aligns with
the dent of center case.
19. Remove all the sealant from the oil pressure check port and
inside the center case.
CAUTION:
Remove old sealant adhering to mounting surfaces. Also
remove any moisture, oil, or foreign material adhering to
application and mounting surfaces.
20. Thread the oil pressure check plug in 1 or 2 pitches and apply
sealant to the oil pressure check plug threads. Tighten to the
specified torque. Refer to TF-144, "
COMPONENTS" .
Use Genuine Silicone RTV or equivalent. Refer to GI-45,
"Recommended Chemical Products and Sealants" .
CAUTION:
Do not reuse oil pressure check plug.
21. Install the snap ring to the clutch hub, using suitable tool.
CAUTION:
Do not reuse snap ring.
SDIA2189E
SDIA2190E
SMT915C
WDIA0101E