Transfer Case: Service Precautions

TRANSFER SYSTEM (4WD)
PRECAUTION
^ Before disassembly, clean the transfer assembly and remove any deposited sand or mud to prevent it from entering the inside of the transfer during disassembly and assembly.
^ When removing any light alloy part such as a transfer cover, do not pry it off with a tool like a screwdriver but tap it out with a plastic hammer.
^ Always organize the removed parts properly and protect them from dust.
^ Before installation, clean all parts and dry them completely and then, apply hypoid gear oil to each part. Do not use alkaline chemicals when cleaning aluminum or rubber parts and ring gear set bolts. Also, do not use any cleansing oil (ex. white gasoline) to clean the rubber parts such as O-rings and oil seals.
^ Apply hypoid gear oil to any sliding surface or rotating part.
^ Do not directly hold a part by a vise. Make sure that you put an aluminum sheet between them.
^ Replace any damaged or deformed snap ring with a new one.
^ If there is a scratch on the mating surface of the case, it may cause oil leakage. Therefore, be careful not to damage the contact surface when handling it.
^ Before applying a sealant, completely remove old sealant stuck on sealed parts and clean them with white gasoline.
^ Do not supply oil immediately after installing sealed parts. Leave 1 hour or more.
^ Scratches on a contact surface of an oil seal, O ring or gasket may cause oil leakage. Be careful not to damage the contact surface when handling it.
^ When press-fitting an oil seal, be careful not to damage the oil seal lip and its periphery.
^ When replacing a bearing, replace both outer and inner races as one set.