Transfer Assembly

TRANSFER ASSEMBLY

Components:

DISASSEMBLY
1. REMOVE BREATHER HOSE
2. REMOVE VEHICLE SPEED SENSOR DRIVEN GEAR
a. Remove the bolt and driven gear.

3. REMOVE MOTOR ACTUATOR
a. Remove the 4 bolts and motor actuator.

4. REMOVE OUTPUT GEAR

5. REMOVE SCREW PLUG
a. Using a T40 "torx" socket, remove the screw plug.
6. REMOVE SPRING
a. Using a magnetic finger, remove the spring.
7. REMOVE BALL
a. Using a magnetic finger, remove the ball.
8. REMOVE TRANSFER INDICATOR SWITCH
a. Remove the 3 indicator switches and 3 gaskets.

9. REMOVE FRONT TRANSFER EXTENSION HOUSING SUB-ASSEMBLY
a. Remove the 6 bolts and extension housing.

HINT: If necessary, tap the extension housing lightly with a plastic-faced hammer.

10. REMOVE CLUTCH SLEEVE WITH NO. 2 SHIFT FORK SHAFT AND NO. 2 SHIFT FORK

11. SEPARATE NO. 2 SHIFT FORK SHAFT AND NO. 2 SHIFT FORK
a. Using 2 screwdrivers and a hammer, tap out the 3 snap rings from the No. 2 shift fork shaft.
b. Separate the No. 2 shift fork shaft and No. 2 shift fork.

12. REMOVE REAR TRANSFER EXTENSION HOUSING SUB-ASSEMBLY
a. Remove the 9 bolts and extension housing.

HINT: If necessary, tap the extension housing lightly with a plastic-faced hammer.

13. REMOVE ADJUSTING SHIM
a. Remove the adjusting shims.

14. REMOVE OIL STRAINER ASSEMBLY
a. Remove the 2 bolts and oil strainer.

15. REMOVE CASE COVER
a. Remove the 5 bolts.

b. Using a brass bar and hammer, tap the case cover and remove it.

16. SEPARATE FRONT CASE AND REAR CASE
a. Using a snap ring expander, remove the snap ring from the rear case.

b. Remove the 8 bolts.
c. Using a brass bar and hammer, tap the rear case and separate it.

17. REMOVE BEARING RACE
a. Remove the 2 bearing races from the rear case.

18. REMOVE INPUT SHAFT SUB-ASSEMBLY
a. Using a plastic-faced hammer, remove the input shaft from the front case.

19. REMOVE IDLER GEAR ASSEMBLY WITH CENTER DIFFERENTIAL ASSEMBLY, NO. 1 SHIFT FORK SHAFT AND NO. 1 SHIFT FORK
a. Remove the idler gear with center differential, No. 1 shift fork shaft and No. 1 shift fork from the front case.

20. SEPARATE NO. 1 SHIFT FORK SHAFT AND NO. 1 SHIFT FORK
a. Using a pin punch and hammer, tap out the slotted spring pin.
b. Separate the No. 1 shift fork and No. 1 shift fork shaft.

21. REMOVE OUTER SHIFT LEVER AND INNER SHIFT LEVER
a. Remove the nut and washer from the outer shift lever.
b. Using a brass bar, hammer and socket wrench, tap out the lever lock pin.
c. Remove the outer shift lever, washer and inner shift lever from the front case.

22. REMOVE INNER SHIFT LEVER OIL SEAL
a. Using a screwdriver, pry out the oil seal from the front case.

23. REMOVE INPUT SHAFT OIL SEAL
a. Using SST and a hammer, tap out the oil seal.
SST 09316-60011 (09316-00011)

24. REMOVE OIL RECEIVER
a. Remove the bolt and oil receiver from the front case.

25. REMOVE BEARING RACE
a. Using SST, remove the bearing race (for the idler gear).
SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010), 09950-60010 (09951-00320)

b. Using a brass bar and hammer, tap out the bearing race (for the output shaft) from the front case.

REASSEMBLY

1. CHECK NO. 2 SHIFT FORK AND CLUTCH SLEEVE CLEARANCE
a. Using a feeler gauge, measure the clearance between the No. 2 shift fork and clutch sleeve.
Standard clearance: 0.10 to 0.40 mm (0.0039 to 0.0157 inch)
Maximum clearance: 0.40 mm (0.0157 inch)
If the clearance is greater than the maximum, replace the No. 2 shift fork or clutch sleeve.

2. INSTALL BEARING RACE (OUTPUT SHAFT)
a. Using SST and a press, press in the bearing race to the front case.
SST 09316-60011 (09316-00011, 09316-00031), 09950-60020 (09951-00890)

3. INSTALL BEARING RACE (IDLER GEAR)
a. Using SST and a press, press in the bearing race to the front case.
SST 09316-60011 (09316-00031, 09316-00011), 09950-60020 (09951-00890)

4. INSTALL OIL RECEIVER
a. Install the oil receiver to the front case with the bolt.
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)

5. INSTALL INPUT SHAFT OIL SEAL
a. Apply MP grease to the lip of a new oil seal.
b. Using SST and a hammer, tap in the oil seal to the front case.
SST 09316-60011 (09316-00011, 09316-00031)

6. INSTALL INNER SHIFT LEVER OIL SEAL
a. Apply MP grease to the lip of a new oil seal.
b. Using SST and a hammer, tap in the oil seal to the front case.
SST 09950-60010 (09951-00270), 09950-70010 (09951-07150)

7. INSTALL OUTER SHIFT LEVER AND INNER SHIFT LEVER
a. Install the inner shift lever, washer and outer shift lever to the front case.
b. Using a pin punch, hammer and socket wrench, tap in the lever lock pin.
c. Install the washer and nut to the outer shift lever.
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)

8. ASSEMBLE NO. 1 SHIFT FORK AND NO. 1 SHIFT FORK SHAFT
a. Assemble the No. 1 shift fork and No. 1 shift fork shaft.
b. Using a pin punch and hammer, tap in the slotted spring pin.

9. INSTALL IDLER GEAR ASSEMBLY WITH CENTER DIFFERENTIAL ASSEMBLY, NO. 1 SHIFT FORK AND NO. 1 SHIFT FORK SHAFT

NOTICE: Set the shift inner lever into the fork head part of the No. 1 shift fork securely.

10. INSTALL INPUT SHAFT SUB-ASSEMBLY
11. INSTALL BEARING RACE
a. Install the 2 bearing races to the rear case.

12. ASSEMBLE FRONT CASE AND REAR CASE
a. Apply FIPG to the front case.
FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent
b. Assemble the front case and rear case.

c. Apply liquid sealer to the "A" bolt threads.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
d. Install the 8 bolts.
Torque: 37 Nm (380 kgf-cm, 27 ft. lbs.)

e. Using a snap ring expander, install the snap ring to the rear case.

13. INSTALL CASE COVER
a. Apply FIPG to the rear case.
FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent
b. Install the case cover.

c. Apply liquid sealer to the bolt threads.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
d. Install the 5 bolts.
Torque: 37 Nm (380 kgf-cm, 27 ft. lbs.)

14. INSTALL OIL STRAINER ASSEMBLY
a. Install the oil strainer to the rear case with the 2 bolts.
Torque: 4.9 Nm (50 kgf-cm, 43 inch lbs.)

15. SELECT ADJUSTING SHIM (REAR IDLER GEAR TAPER ROLLER BEARING)
a. Using a vernier caliper, measure dimension "A".
b. Lightly hold down the outer bearing race in the thrust direction to eliminate any looseness before making the measurement.

c. Using a steel straightedge and feeler gauge, measure the clearance of dimension "B".
d. Calculate the required thickness of the adjusting shim.
Standard thickness: Dimension "A" + Dimension "B" + (0.022 to 0.049 mm, (0.0009 to 0.0019 inch))

e. From the following table, select a shim so that its thickness is within the range of the calculation. Standard snap ring thickness

16. SELECT ADJUSTING SHIM (OUTPUT SHAFT TAPER ROLLER BEARING)
a. Using a steel straightedge and feeler gauge, measure the clearance of dimension "C".
b. Lightly hold down the bearing outer race in the thrust direction to eliminate any looseness before making the measurement.

c. Using a steel straightedge and vernier caliper with depth gauge, measure dimension "D".
d. Dimension "D" is the straightedge thickness (Dimension "F") subtracted from dimension "E" in the illustration.
Dimension "D": Dimension "E" - Dimension "F"
e. Using a steel straightedge and vernier caliper with depth gauge, measure dimension "G".

f. Dimension "G" is the straightedge thickness (Dimension "F") subtracted from Dimension "H".
Dimension "G": Dimension "H" -Dimension "F"
g. Calculate the require thickness of the adjusting shim.
Thickness: Dimension "G" - (Dimension "D" - Dimension "C") + (0.014 to 0.039 mm (0.0006 to 0.0015 inch)
h. From the following table, select a shim so that its thickness is within the range of the calculation.

Standard Snap Ring Thickness:

17. INSTALL REAR TRANSFER EXTENSION HOUSING SUB-ASSEMBLY
a. Apply FIPG to the extension housing.
FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent

b. Install the extension housing with the 9 bolts.
Torque: 37 Nm (380 kgf-cm, 27 ft. lbs.)

18. ASSEMBLE NO. 2 SHIFT FORK SHAFT AND NO. 2 SHIFT FORK
a. Install the No. 2 shift fork to the No. 2 shift fork shaft.
b. Install the 3 snap rings to the No. 2 shift fork shaft.
19. INSTALL CLUTCH SLEEVE WITH NO. 2 SHIFT FORK SHAFT AND NO. 2 SIFT FORK

HINT: Make sure to install the clutch sleeve in the correct direction.

20. INSTALL FRONT TRANSFER EXTENSION HOUSING SUB-ASSEMBLY
a. Apply FIPG to the extension housing.
FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent

b. Install the extension housing with the 6 bolts.
Torque: 37 Nm (380 kgf-cm, 27 ft. lbs.)

HINT: Set the clutch sleeve in differential lock condition.

21. INSTALL TRANSFER INDICATOR SWITCH
a. Install the 3 indicator switches with 3 new gaskets.
Torque: 37 Nm (380 kgf-cm, 27 ft. lbs.)

22. INSTALL BALL
23. INSTALL SPRING
24. INSTALL SCREW PLUG
a. Apply liquid sealer to the screw plug threads.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
b. Using a T40 "torx" socket, install the screw plug.
Torque: 19 Nm (190 kgf-cm, 14 ft. lbs.)

25. INSTALL OUTPUT GEAR
a. Apply gear oil to the output gear.
b. Install the output gear to the front case.

NOTICE: Do not turn the output gear.

26. INSTALL MOTOR ACTUATOR
a. Apply FIPG to the motor actuator.
FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent

HINT: Set the motor actuator in differential lock condition.

b. Install the motor actuator with the 4 bolts.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)
27. INSTALL VEHICLE SPEED SENSOR DRIVEN GEAR
a. Install the driven gear with the bolt.
Torque: 11 Nm (115 kgf-cm, 8 ft. lbs.)
28. INSTALL BREATHER HOSE