Assembly

HINT: Coat all of the sliding and rotating surface with gear oil before assembly.




1. ADJUST RING GEAR BACKLASH
a. Install the adjusting shim to the driven pinion bearing cage assembly.

HINT: First install a shim of the same thickness as before.




b. Install the driven pinion bearing cage assembly to the transfer left case.
c. Install and torque the six bolts.

Torque: 400 kg-cm (29 ft-lb, 39 N-m)

HINT: Do not install the O-ring.




d. Install the ring gear mounting case assembly to the transfer left case.




e. Using a dial indicator, measure the ring gear backlash.

Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 in.)




f. Referring to the table, select the plate washer which will ensure that the backlash is within specification. Try to select a washer of the same size.

HINT: The backlash will change about 0.02 mm (0.0008 in.) with each shim thickness.




2. ADJUST TOTAL PRELOAD
a. Install the transfer right case.
b. Install and torque the twelve bolts.

Torque: 450 kg-cm (33 ft-lb, 44 N-m)




c. Adjust the total preload by tightening the bearing adjusting nut.
Using SST, tightening the adjusting nut.
SST 09318-20010

HINT: Measure the preload while tightening the adjusting nut a little at a time.

d. Using SST and a spring tension gauge, measure the total preload.
SST 09326-20011

Preload (at starting):
New bearing
Add driven pinion preload 1.3 - 1.4 kg
(2.9 - 3.1 lb, 13 - 14 N)
Reused bearing
Add driven pinion preload 0.5 - 0.9 kg
(1 - 2 lb, 5 - 9 N)

HINT: Turn the output shaft counterclockwise and clockwise several times.




e. When the standard value for total preload is exceeded, remove the transfer right case, push in the adjusting nut and outer race. Again adjust the total preload.




3. CHECK RING GEAR BACKLASH
a. Using a dial indicator, measure the ring gear backlash.

Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 in.)

b. When the backlash is outside the standard value, select a different plate washer to the one selected step 2. Again adjust the backlash and total preload.




4. CHECK TOOTH CONTACT
a. Coat 3 or 4 teeth at four different position on the ring gear with red lead.
b. Rotate the ring gear, inspect the teeth pattern.







c. If the teeth are not contacting properly, again select the proper shim and plate.




5. REMOVE RING GEAR MOUNTING CASE ASSEMBLY
a. Remove the twelve bolts and transfer right case.




b. Remove the ring gear mounting case assembly.




6. REMOVE DRIVEN PINION BEARING CAGE ASSEMBLY
Remove the six bolts and bearing cage assembly.




7. INSTALL DRIVEN PINION BEARING CAGE ASSEMBLY
a. Coat the O-ring with gear oil.
b. Install the O-ring to the driven pinion bearing cage.
c. Install the driven pinion bearing cage with the adjusting shim (previously selected) to the transfer left case.
d. Install and torque the six bolts.

Torque: 400 kg-cm (29 ft-lb, 39 N-m)




8. INSTALL RING GEAR MOUNTING CASE ASSEMBLY




9. INSTALL TRANSFER RIGHT CASE
a. Remove any packing material and be careful not to drop oil on the contacting surfaces of the transfer left case or right case.
b. Apply seal packing to the transfer left case as shown in the figure.

Seal packing: Part No.08826-00090, THREE BOND 1281 or equivalent

HINT: Install the transfer right case as soon as the seal packing is applied.




c. Apply sealant to the bolt threads.

Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent

d. Install and torque the twelve bolts.

Torque: 450 kg-cm (33 ft-lb, 44 N-m)

10. CHECK TOTAL PRELOAD




11. INSTALL ADJUSTING NUT LOCK PLATE
Using snap ring pliers, install the lock plate so that the projection from the lock plate fits properly into the groove of the adjusting nut.

HINT: Choose one of the two types of lock plate can be installed, tighten the adjusting nut to the minimum limit.




12. INSTALL SIDE GEAR SHAFT HOLDER
a. Install the side gear shaft holder to the transfer right case.
b. Using snap ring pliers, install the snap ring.




13. INSTALL OIL SEAL
a. Coat the lip of the oil seal with MP grease.
b. Using a brass bar and hammer, drive in a new oil seal.




14. INSTALL TRANSFER INSPECTION HOLE COVER
a. Remove any packing material and be careful not to drop oil on the contacting surfaces of transfer left case or transfer inspection hole cover.
b. Apply seal packing to the transfer left case as shown in the figure.

Seal packing: Part No.08826-00090, THREE BOND 1281 or equivalent

HINT: Install the transfer inspection hole cover as soon as the seal packing is applied.




c. Install and torque the three bolts.

Torque: 160 kg-cm (12 ft-lb, 16 N-m)




15. INSTALL DIFFERENTIAL LOCK SHIFT FORK SHAFT
a. Install the differential lock sleeve with shift fork.
b. Install the shift fork shaft to the transfer case.
c. Install and torque the bolt.

Torque: 160 kg-cm (12 ft-lb. 16 N-m)




d. Install the transfer case upper cover bushing.




e. Install the inner lever in the shift fork shaft groove. Insert the shift lever shaft and Install the E-ring.




f. Using SST, install and torque the plug.
SST 09043-38100

Torque: 400 kg-cm (29 ft-lb, 39 N-m)




16. INSTALL LOCKING BALL, SPRING, SEAT AND PLUG
a. Using magnetic finger, Install the locking ball, spring and seat.




b. Apply sealant to the plug threads.

Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent

c. Using SST, install and torque the plug.
SST 09313-30021

Torque: 250 kg-cm (18 ft-lb, 25 N-m)




17. INSTALL TRANSFER CASE COVER
a. Install the new gasket and case cover.
b. Install and torque the four bolts.

Torque: 175 kg-cm (13 ft-lb, 17 N-m)




c. Install the bolt to the shift lever shaft as shown.

Torque: 200 kg-cm (14 ft-lb, 20 N-m)




18. INSTALL EXTENSION HOUSING
a. Coat the O-ring with gear oil.
b. Install the O-ring to the extension housing.
c. Install the extension housing to the driven pinion bearing cage.
d. Install and torque the four bolts.

Torque: 260 kg-cm (19 ft-lb, 25 N-m)




19. INSTALL DYNAMIC DAMPER
Install and torque the four bolts.

Torque: 260 kg-cm (19 ft-lb, 25 N-m)