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TF–10TRANSFER – TRANSFER ASSEMBLY
TF
6. INSTALL NO. 1 TRANSFER CASE PLUG
(a) Add oil up to 0 to 5 mm below the lower side of the
plug hole.
Oil quantity:
0.9 L (0.95 US qts, 0.71 lmp. qts)
HINT:
When adding oil, pour it slowly.
(b) Install the No. 1 transfer case plug with a new No. 1
gasket.
Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf)
7. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
HINT:
(See page SP-4)
8. CHECK ABS SPEED SENSOR SIGNAL
HINT:
(See page BC-3)
Page 2034 of 3000
TRANSFER – TRANSFER UNITTF–11
TF
DRIVE LINE
TRANSFER
TRANSFER UNIT
COMPONENTS
C118782E04
Page 2035 of 3000
TF–12TRANSFER – TRANSFER UNIT
TF
C118783E03
Page 2036 of 3000
TRANSFER – TRANSFER UNITTF–13
TF
DISASSEMBLY
1. REMOVE TRANSFER COVER GASKET
(a) Remove the transfer gasket from the transfer
assembly.
2. REMOVE TRANSFER CASE BREATHER PLUG
(a) Using a screwdriver and a hammer, remove the
transfer case breather plug from the No. 1 transfer
case cover.
NOTICE:
Be careful not to damage the contact surface of
No. 1 case cover.
3. REMOVE NO. 1 TRANSFER CASE COVER
(a) Remove the 8 bolts.
(b) Using a brass bar and a hammer, remove the No. 1
transfer case cover from the transfer case.
NOTICE:
Be careful not to damage the contact surfaces of
the case and cover.
4. REMOVE BREATHER OIL DEFLECTOR
(a) Remove the bolt and breather oil deflector from the
No. 1 transfer case cover.
C082798
C094714
C083507
C050303
C067665
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TF–14TRANSFER – TRANSFER UNIT
TF
5. REMOVE TRANSFER DYNAMIC DAMPER
(a) Remove the 3 bolts and the transfer dynamic
damper from the transfer extension housing sub-
assembly.
6. REMOVE TRANSFER CASE STRAIGHT PIN
(a) Remove the 4 transfer case straight pins from the
transfer case.
7. REMOVE TRANSFER AND TRANSAXLE SETTING
STUD BOLT
(a) Remove the 4 transfer and transaxle setting stud
bolts.
8. FIX TRANSFER ASSEMBLY
(a) Fix the transfer assembly to the overhaul
attachment.
9. REMOVE TRANSFER EXTENSION HOUSING DUST
DEFLECTOR
(a) Using a plastic hammer, remove the transfer
extension housing dust deflector from the transfer
extension housing sub-assembly.
10. REMOVE TRANSFER EXTENSION HOUSING TYPE T
OIL SEAL
(a) Using SST(s), remove the transfer extension
housing type T oil seal from the transfer extension
housing.
SST 09308-00010
NOTICE:
Be careful not to damage the oil-seal-fitted
surface of the housing and the inside surface of
the bush.
11. REMOVE TRANSFER EXTENSION HOUSING SUB-
ASSEMBLY
(a) Remove the 4 bolts.
C082802
C082788
C082978E01
C082790
Page 2038 of 3000
TRANSFER – TRANSFER UNITTF–15
TF
(b) Using a plastic hammer, remove the transfer
extension housing sub- assembly from the transfer
case.
12. INSPECT PRELOAD
(a) Using SST(s) and a torque wrench, check the initial
torque with the backlash range.
SST 09326-20011
Torque: 0.9 to 1.4 N*m (9 to 14 kgf*cm, 8.0 to
12.4 in.*lbf)
HINT:
Use a torque wrench with a fulcrum length of 160
mm (6.30 in.)
(b) Using SST(s) and a torque wrench, check the initial
torque while the driven pinion is in contact with the
ring gear face.
SST 09326-20011
Torque: Preload
+ 0.15 to 0.30 N*m (+ 1.6 to 3.1 kgf*cm, +
1.3 to 2.7 in.*lbf)
HINT:
Use a torque wrench with a fulcrum length of 160
mm (6.30 in.)
13. REMOVE CTR DIFFERENTIAL LOCK SLEEVE
(a) Using snap ring pliers, remove the shaft snap ring.
(b) Using SST(s), remove the CTR differential lock
sleeve.
SST 09308-00010
C082791
C083635E01
C083637
C083638E01
Page 2039 of 3000
TF–16TRANSFER – TRANSFER UNIT
TF
14. REMOVE O-RING
(a) Using a screwdriver with the tip protected by vinyl
tape, remove the O-ring from the CTR differential
lock sleeve.
NOTICE:
Be careful not to damage the lock sleeve's
groove for the O-ring.
15. REMOVE TRANSFER CASE OIL SEAL
(a) Using SST(s), remove the transfer case oil seal
from the case.
SST 09308-00010
NOTICE:
Be careful not to damage the oil-seal-fitted
surface of the case.
16. REMOVE TRANSFER RH BEARING RETAINER OIL
SEAL
(a) Using SST(s), remove the transfer RH bearing
retainer oil seal from the transfer RH bearing
retainer sub-assembly.
SST 09308-00010
NOTICE:
Be careful not to damage the oil-seal-fitted
surface of the retainer.
17. REMOVE TRANSFER RH BEARING RETAINER SUB-
ASSEMBLY
(a) Remove the 7 bolts from the transfer RH bearing
retainer sub-assembly.
C050311
C083630E02
C082980E01
C083509
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TRANSFER – TRANSFER UNITTF–17
TF
(b) Using SST, make a clearance between the transfer
RH bearing retainer sub-assembly and the transfer
case.
SST 09950-00020
(c) Remove the SST.
(d) Using SST, remove the transfer RH bearing retainer
sub-assembly from the transfer case.
SST 09520-10021
18. REMOVE O-RING
(a) Using a screwdriver with the tip protected by vinyl
tape, remove the 2 O-rings from the transfer RH
bearing retainer sub-assembly.
NOTICE:
Be careful not to damage the retainer's grooves
for the O-rings.
19. REMOVE CENTER DIFFERENTIAL CASE TAPERED
ROLLER BEARING
(a) Fix the transfer RH bearing retainer sub-assembly
in a vise.
(b) Using SST(s), remove the center differential case
tapered roller bearing RH outer race, transfer ring
gear mounting case washer No. 2 and right bearing
retainer oil seal No. 2 from the transfer RH bearing
retainer sub-assembly.
SST 09308-00010
NOTICE:
Be careful not to damage the oil-seal-fitted
surface of the transfer RH bearing retainer sub-
assembly.
C149592E01
C082981E06
C050313
C083639E01