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TRANSFER – TRANSFER UNITTF–35
TF
(c) Using SST(s), install the CTR differential lock sleeve
to the transfer case.
SST 09950-60010 (09951-00610), 09950-70010
(09951-07150)
(d) Using snap ring pliers, install the shaft snap ring.
NOTICE:
Check that the snap ring is fitted in the groove
of the ring gear mounting case.
30. INSTALL TRANSFER EXTENSION HOUSING TYPE T
OIL SEAL
(a) Using SST(s), install the transfer extension housing
type T oil seal to the transfer extension housing at
the position as shown in the illustration.
SST 09950-60010 (09951-00380, 09951-00580,
09951-07150, 09952-06010), 09950-70010
NOTICE:
Install the oil seal carefully so that it will not be
tilted.
(b) Apply small amount of MP grease No. 2 to the oil
seal lip.
31. INSTALL TRANSFER EXTENSION HOUSING DUST
DEFLECTOR
(a) Using SST(s) and press, install a new transfer
extension housing dust deflector to the transfer
extension housing sub-assembly.
SST 09950-60020 (09951-00710), 09950-70010
(09951-07150)
C083692E01
C083693
C083694E01
C083695E01
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TF–36TRANSFER – TRANSFER UNIT
TF
32. INSTALL TRANSFER EXTENSION HOUSING SUB-
ASSEMBLY
(a) Apply sealant 1281 to the transfer extension
housing sub-assembly in continuous beaded from of
1.2 mm diameter as show in the illustration.
NOTICE:
• Wipe any grease off from the attaching
surfaces.
• Install the transfer extension housing sub-
assembly within 10 minutes after applying the
sealant.
(b) Install the transfer extension housing sub-assembly
to the transfer case with the 4 bolts.
Torque: 26 N*m (260 kgf*cm, 19 ft.*lbf)
(c) Remove the transfer assembly from the overhaul
attachment.
33. INSTALL TRANSFER AND TRANSAXLE SETTING
STUD BOLT
(a) Install the transfer and transaxle setting stud bolts to
the parts of the transfer case as show in the
illustration.
Torque: 39 N*m (400 kgf*cm, 30 ft.*lbf)
NOTICE:
Install the sealant-coated side of the transfer
and transaxle stud bolt to the transfer case.
34. INSTALL TRANSFER CASE STRAIGHT PIN
(a) Using a plastic hammer, install the transfer case
straight pins to the transfer case as shown in thee
illustration.
C083696E01
C082800
D031105E01
C083712E01
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TRANSFER – TRANSFER UNITTF–37
TF
35. INSTALL TRANSFER DYNAMIC DAMPER
(a) Install the transfer dynamic damper to the transfer
extension housing sub-assembly with the 3 bolts.
Torque: 26 N*m (260 kgf*cm, 19 ft.*lbf)
36. INSTALL BREATHER OIL DEFLECTOR
(a) Install the breather oil deflector to the transfer case
cover No. 1 with the bolt.
Torque: 6.5 N*m (66 kgf*cm, 57 in.*lbf)
NOTICE:
Be careful about the direction of the deflector's
fold.
37. INSTALL NO. 1 TRANSFER CASE COVER
(a) Apply sealant 1281 to the transfer case cover No. 1
in a continuous bead of 1.2 mm diameter as show in
the illustration.
NOTICE:
• Wipe any grease off from the attaching
surfaces.
• Install the transfer case cover No. 1 within 10
minutes after application of the sealant.
(b) Install the transfer case cover No. 1 to the transfer
case with 8 bolts.
Torque: 20 N*m (200 kgf*cm, 14 ft.*lbf)
38. INSTALL TRANSFER CASE BREATHER PLUG
(a) Using SST(s) and a hammer, install the transfer
case breather plug to the transfer case cover No. 1.
SST 09612-10093 (09612-10061)
C051143
C067686
C083713E01
C083507
D030774E01
Page 2028 of 3000
TF–38TRANSFER – TRANSFER UNIT
TF
39. INSTALL TRANSFER COVER GASKET
(a) Install a new transfer cover gasket to the transfer
case.
C082798
Page 2029 of 3000
TRANSFER – TRANSFER OILTF–3
TF
TRANSFER OIL
ON-VEHICLE INSPECTION
1. INSPECT TRANSFER OIL
(a) Remove the No. 1 plug and gasket.
(b) Check the oil level is within 0 - 5 mm (0 - 0.20 in.)
below the lowest end of the hole for No. 1 plug.
NOTICE:
• When changing oil, recheck the oil level after
driving.
• Excessively large or small quantity of oil may
cause some trouble.
(c) When the oil level is too low, check for oil leakage.
(d) Tighten the No. 1 plug with a new gasket.
Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf)
2. ADD TRANSFER OIL
(a) Remove the No. 1 plug and gasket and supply oil.
NOTICE:
• When supplying oil, pour it slowly.
• Supply oil several times at several minutes
interval.
HINT:
The oil level should be within 0 - 5 mm (0 - 0.20 in.)
below the lowest end of the hole for the No. 1 plug.
(b) After leaving it alone for 5 minutes, recheck the oil
level.
(c) Tighten the No. 5 plug with a new gasket.
Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf)
C083746E06
Page 2030 of 3000
TRANSFER – TRANSFER ASSEMBLYTF–7
TF
DRIVE LINE
TRANSFER
TRANSFER ASSEMBLY
COMPONENTS
C118798E04
Page 2031 of 3000
TF–8TRANSFER – TRANSFER ASSEMBLY
TF
REMOVAL
1. REMOVE ENGINE AND TRANSAXLE
HINT:
(See page EM-26)
2. REMOVE AUTOMATIC TRANSMISSION WITH
TRANSFER
HINT:
(See page AX-164)
3. REMOVE NO. 1 TRANSFER CASE PLUG
(a) Remove the No. 1 transfer case plug.
(b) Remove the No. 1 gasket from the transfer case No.
1 plug.
4. REMOVE NO. 2 TRANSFER CASE PLUG
(a) Remove the No. 2 transfer case plug.
(b) Remove the No. 2 gasket from the No. 2 transfer
case plug.
5. REMOVE TRANSFER DRAIN PLUG
(a) Remove the transfer drain plug and bleed the oil.
(b) Remove the drain gasket from the transfer drain
plug.
6. REMOVE TRANSFER ASSEMBLY
(a) Remove the 2 bolts and 6 bolts.
(b) Using a plastic hammer, remove the transfer
assembly from the transaxle assembly.
NOTICE:
• Remove the transfer assembly from the
transaxle assembly without tilting it.
• When removing the transfer assembly, do not
hold onto the oil seal parts on both sides of
the assembly.
C082977E01
C082785E01
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TRANSFER – TRANSFER ASSEMBLYTF–9
TF
INSTALLATION
1. INSTALL TRANSFER ASSEMBLY
(a) Apply sealant 1281 to the transaxle assembly and
transfer assembly in continuous beaded from of 1.2
mm diameter as shown in the illustration.
NOTICE:
• Wipe any grease off from the attaching
surfaces.
• Install it within 10 minutes after applying the
sealant.
• Sealant stuck on the gasket, case oil seal and
driving plug may cause oil leakage and
seizure due to oil shortage. Care must be
taken.
(b) Install the transfer assembly to the transaxle
assembly with the 2 bolts and 6 nuts.
Torque: 69 N*m (700 kgf*cm, 51 ft.*lbf)
NOTICE:
• Check that the gasket is installed to the
transfer assembly before installing them to
the transaxle assembly.
• Install the transfer assembly to the transaxle
assembly without tilting.
• When moving the transfer assembly, do not
hold the oil seal on the both sides.
2. INSTALL AUTOMATIC TRANSMISSION WITH
TRANSFER
HINT:
(See page AX-167)
3. INSTALL ENGINE AND TRANSAXLE
HINT:
(See page EM-44)
4. INSTALL TRANSFER DRAIN PLUG
(a) Install the transfer drain plug with a new drain
gasket.
Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf)
5. INSTALL NO. 2 TRANSFER CASE PLUG
(a) Install the No. 2 transfer case plug with a new No. 2
gasket.
Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf)
C083714E01
C082785
C082977E01