Disassembly

1. REMOVE DYNAMIC DAMPER
Remove the four bolts and dynamic damper.




2. REMOVE EXTENSION HOUSING
a. Remove the four bolts and tap off the housing with a plastic hammer.
b. Remove the O-ring from the extension housing.




3. REMOVE TRANSFER CASE COVER
a. Remove the five bolts.
b. Remove the case cover and gasket.




4. REMOVE SHIFT LEVER SHAFT AND INNER LEVER
a. Remove the E-ring.
b. Remove the shift lever shaft and inner lever.




5. REMOVE TRANSFER CASE UPPER BUSHING




6. REMOVE PLUG, SEAT, SPRING AND LOCKING BALL
a. Using SST, remove the plug.
SST 09313-30021




b. Using a magnetic finger, remove the seat, spring and ball.




7. REMOVE DIFFERENTIAL LOCK SHIFT FORK AND SHIFT FORK SHAFT
a. Using SST, remove the plug.
SST 09043-38100




b. Remove the set bolt.
c. Remove the differential lock sleeve and shift fork.




d. Pull out the shift fork shaft.




8. REMOVE SIDE GEAR SHAFT HOLDER
a. Using a screwdriver and hammer, remove the oil seal.




b. Using snap ring pliers, remove the snap ring.




c. Remove the shaft holder.




9. CHECK PRELOAD
a. Using SST and a spring tension gauge, measure the driven pinion preload of the backlash between the driven pinion and ring gear.
SST 09326-20011

Preload (at starting): 0.9 - 1.4 kg
(2 - 3 lb, 9 - 14 N)

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

Total preload (at starting):
Add driven pinion preload
0.5 - 0.9 kg (1 - 2 lb, 5 - 9 N)




10. REMOVE TRANSFER INSPECTION HOLE COVER
Remove the three bolts and a cover.




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

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

12. CHECK TOOTH CONTACT




13. REMOVE DRIVEN PINION BEARING CAGE ASSEMBLY
a. Remove the six bolts and tap off the bearing cage assembly with a plastic hammer.
b. Remove the O-ring from the driven pinion bearing cage.




14. REMOVE TRANSFER RIGHT CASE
Remove the twelve bolts and tap off the case with a plastic hammer.




15. REMOVE RING GEAR MOUNTING CASE ASSEMBLY




16. REMOVE ADJUSTING NUT LOCK PLATE
Using snap ring pliers, remove the lock plate from the transfer right case.




17. IF NECESSARY, REPLACE EXTENSION HOUSING OIL SEAL
a. Using a screwdriver, remove the oil seal.




b. Using SST and a hammer, drive in a new oil seal.
SST 09325-20010

Oil seal depth: 1.1 - 1.9 mm (0.043 - 0.075 in.)

c. Coat the lip of oil seal with MP grease.




18. IF NECESSARY. REPLACE DIFFERENTIAL LOCK SHIFT LEVER SHAFT OIL SEAL
a. Using a screwdriver, remove the oil seal.




b. Coat the lip of oil seal with MP grease.
c. Using SST and a hammer, drive in a new oil seal.
SST 09620-30010 (09625-30010, 09631-00020)

Oil seal depth: 1.0 - 2.0 mm (0.039 - 0.079 in.)




19. IF NECESSARY. REPLACE SHIFT FORK SHAFT OIL SEAL
a. Using a screwdriver and hammer, remove the oil seal.




b. Coat the lip of the oil seal with MP grease.
c. Using SST and a hammer, drive in a new oil seal as shown.
SST 09620-30010 (09625-30010, 09631-00020)

Oil seal height: 8.5 - 9.5 mm (0.335 - 0.374 in.)




20. IF NECESSARY, REPLACE SIDE GEAR SHAFT HOLDER BEARING
a. Using snap ring pliers, remove the snap ring.




b. Using a press, remove the bearing from the side gear shaft holder.




c. Using SST and a press, install a new bearing as shown.
SST 09316-60010 (09316-00010)




d. Using snap ring pliers, install the snap ring.




21. IF NECESSARY, REPLACE TRANSFER OIL TUBE
a. Remove the bolt and oil tube.




b. Using a screwdriver, remove the cushion.




c. Install a new cushion.




d. Install the oil tube.
e. Install and torque the bolt.

Torque: 130 kg-cm (9 ft-lb, 13 N-m)




22. IF NECESSARY, REPLACE RING GEAR MOUNTING CASE SIDE BEARING OUTER RACE
(Transfer Right Case)
a. Using SST, turn the bearing adjusting nut, remove the outer race and bearing adjusting nut.
SST 09318-20010




b. Install the bearing adjusting nut until it touches the lip of the case.

HINT: If the nut is difficult to turn, use SST (09318-20010)




c. Using SST and a press, install the bearing outer race until it is almost touching the bearing adjusting nut.
SST 09608-35014 (09608-06020, 09608-06180)




(Transfer Left Case)
a. Using a brass bar and hammer, drive out the bearing outer race lightly and evenly.
b. Remove the plate washer.




c. Install the plate washer.

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




d. Using SST and a press, install the outer race.
SST 09316-60010 (09316-00010, 09316-00060)