Part 1

TRANSFER ASSY



































COMPONENTS

OVERHAUL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. DRAIN TRANSFER OIL





3. REMOVE TRANSFER CASE LOWER PROTECTOR
a. Remove the 4 bolts and the transfer case lower protector.
4. REMOVE MANUAL TRANSMISSION UNIT ASSY (R155F TRANSMISSION)

HINT: Refer to the instructions for the removal of the transmission w/ transfer assy.

5. REMOVE MANUAL TRANSMISSION UNIT ASSY (RA60F TRANSMISSION)

HINT: Refer to the instructions for the removal of the transmission w/ transfer assy.

6. REMOVE AUTOMATIC TRANSMISSION ASSY (A750F TRANSMISSION)

HINT: Refer to the instructions for the removal of the transmission w/ transfer assy.





7. REMOVE TRANSFER ASSY
a. Remove the 8 transfer adaptor rear mounting bolts.
b. Pull the transfer straight up and remove it from the transmission.

HINT: Take care not to damage the adaptor rear oil seal with the transfer input gear spline.





8. REMOVE TRANSFER CASE COVER SUB-ASSY
a. Remove the 4 bolts and the case cover sub-assembly.
9. REMOVE BREATHER OIL DEFLECTOR SUB-ASSY





10. REMOVE TRANSFER RH BEARING RETAINER SUB-ASSY
a. Remove the 5 bolts and the front bearing retainer sub-assembly.

HINT: If necessary, tap the retainer sub-assembly with a plastic hammer to remove it.

11. REMOVE TRANSFER RH BEARING RETAINER OIL SEAL (R155F/A750F TRANSMISSION)
a. Using a screwdriver and hammer, remove the transfer RH bearing retainer oil seal.
12. REMOVE TRANSFER RH BEARING RETAINER OIL SEAL (RA60F TRANSMISSION)
a. Using a screwdriver and hammer, remove the 2 transfer RH bearing retainer oil seals.





13. REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSY
a. Using a chisel and hammer, loosen the staked part of the output shaft companion flange lock nut.
b. Using SST to hold the output shaft companion flange, remove the output shaft companion flange lock nut.
SST 09330-00021





c. Using SST, remove the output shaft companion flange sub-assembly (front side).
SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04051, 09957-04010, 09958-04011)
14. REMOVE TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL
a. Using a screwdriver and hammer, remove the companion flange oil seal.
15. REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSY
a. Remove the rear output shaft companion flange sub-assembly using the same procedure as for the front output shaft companion flange sub-assembly (rear side).
SST 09330-00021, 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04051, 09957-04010, 09958-04011)
16. REMOVE TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL
a. Using a screwdriver and hammer, remove the companion flange oil seal.
17. REMOVE SPEEDOMETER DRIVEN GEAR ASSY W/ SENSOR (R155F/RA60F TRANSMISSION)
a. Remove the bolt and speedometer driven gear w/ sensor.
18. REMOVE SPEEDOMETER DRIVEN HOLE COVER SUB-ASSY (A750F TRANSMISSION)
a. Remove the bolt and speedometer hole cover sub-assembly.





19. REMOVE TRANSFER EXTENSION HOUSING SUB-ASSY FRONT
a. Remove the 5 bolts and extension housing sub-assembly.

HINT: If necessary, tap the extension housing sub-assembly with a plastic hammer to remove it.

20. REMOVE TRANSFER EXTENSION HOUSING TYPE T OIL SEAL
a. Using a screwdriver and hammer, remove the type T oil seal.
21. REMOVE TRANSFER OUTPUT WASHER
22. REMOVE TRANSFER SPEEDOMETER DRIVE GEAR
a. Remove the speedometer drive gear.
b. Using a magnetic finger, remove the speedometer drive gear ball.





23. REMOVE TRANSFER CASE REAR
a. Remove the 12 bolts and 2 brackets.
b. Remove the transfer case rear.

HINT: If necessary, tap the transfer case rear with a plastic hammer to remove it.





24. REMOVE TRANSFER FRONT DRIVE SHIFT FORK SHAFT
a. Using a hexagon wrench (6 mm), remove the 2 shift detent ball spring plugs, 2 shift fork compression springs and 2 shift detent balls.





b. Using 2 screwdrivers and a hammer, tap out the 2 shift fork shaft snap rings.





c. Remove the bolt and shift shaft stopper.





d. To pull out the shift fork shaft, shift the shift fork No.1 and No.2 to the positions shown in the illustration.
e. Pull out the shift fork shaft.





f. Using a magnetic finger, remove the 2 shift inter lock pins.





25. REMOVE REAR OUT PUT SHAFT ASSY, FRONT DRIVE CHAIN, DRIVEN SPROCKET ASSY, SHIFT FORK NO.1 AND NO.2
a. Using 2 screwdrivers and a hammer, tap out the shift fork shaft snap ring.

HINT: Remove only the snap ring on the front side of the shift fork shaft.





b. Using a snap ring expander, remove the output shaft snap ring.





c. Mount the transfer case rear in a vise.
d. Using a plastic hammer, carefully tap the transfer case rear and remove the rear output shaft assy, driven sprocket assy, front drive chain, shift fork No.1 and No.2.
e. Remove the driven sprocket assy, front drive chain, shift fork No.1 and No.2 from the rear output shaft assy.





26. REMOVE TRANSFER SHIFT ACTUATOR ASSY
a. Using 2 screwdrivers and a hammer, remove the shift fork shaft snap ring.
b. Remove the 3 bolts and shift actuator assy.





27. REMOVE TRANSFER INDICATOR SWITCH NO.1
a. Remove the O-ring, the 2 indicator switches No.1 and 2 gaskets.





28. REMOVE TRANSFER DRIVEN SPROCKET BEARING
a. Using SST and a press, remove the driven sprocket bearing.
SST 09527-10011





29. REMOVE TRANSFER INPUT GEAR RADIAL BALL BEARING
a. Using SST, a press and steel bar, remove the input gear radial ball bearing.
SST 09555-55010
30. REMOVE TRANSFER CASE PLUG
a. Remove the transfer case plug No.1 (filler plug) and gasket.
31. REMOVE TRANSFER CASE PLUG
a. Remove the transfer case plug (drain plug) and gasket.





32. REMOVE TRANSFER OIL SEPARATOR SUB-ASSY
a. Remove the 3 bolts and oil separator sub-assembly.
33. REMOVE TRANSFER CASE MAGNET





34. REMOVE TRANSFER OIL PUMP BODY SUB-ASSY
a. Remove the 3 bolts and oil pump body sub-assembly.
35. REMOVE TRANSFER OIL PUMP GEAR





36. REMOVE TRANSFER OIL PUMP BODY D-RING
a. Using a screwdriver, remove the oil pump body O-ring.





37. REMOVE LOW PLANETARY GEAR ASSY W/ INPUT SHAFT SUB-ASSY
a. Using a snap ring expander, remove the low planetary gear bearing shaft snap ring.





b. Remove the low planetary gear assy w/ input shaft assy.





38. REMOVE TRANSFER CASE PLUG
a. Remove the case plug.
b. Using a magnetic finger, remove the spring and pin.





39. REMOVE TRANSFER LOW PLANETARY RING GEAR
a. Using a screwdriver, remove the hole snap ring.
b. Remove the low planetary ring gear from the front case.
40. REMOVE TRANSFER CASE OIL SEAL
a. Using a screwdriver and hammer, remove the transfer case oil seal.





41. REMOVE TRANSFER LOW PLANETARY GEAR SPLINE PIECE
a. Using a screwdriver, remove the low planetary gear shaft snap ring.





b. Remove the low planetary gear spline piece.





42. REMOVE TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING





43. REMOVE TRANSFER INPUT GEAR STOPPER SHAFT SNAP RING
a. Using a snap ring expander, remove the input gear stopper shaft snap ring.





44. REMOVE TRANSFER INPUT GEAR STOPPER
45. REMOVE TRANSFER INPUT GEAR STOPPER BALL
46. REMOVE MANUAL TRANSFER PLANETARY CARRIER WASHER





47. REMOVE TRANSFER INPUT SHAFT
48. REMOVE TRANSFER THRUST BEARING RACE NO.1
49. REMOVE TRANSFER LOW PLANETARY GEAR BEARING





50. REMOVE TRANSFER INPUT SHAFT SEAL RING NO.1
a. Remove the 2 seal rings No.1.





51. INSPECT TRANSFER INPUT SHAFT
a. Using a micrometer, measure the outer diameter of the input shaft journal surface.
Minimum diameter: 47.59 mm (1.8736 inch)
If the outer diameter is less than the minimum, replace the input shaft.





b. Using a dial indicator, measure the inside diameter of the input shaft bushing.
Maximum diameter: 39.14 mm (1.5409 inch)
If the inside diameter exceeds the maximum, replace the input shaft.





52. INSPECT SYNCHRONIZER RING
a. Turn the ring and confirm that the input shaft and synchronizer ring are engaged with each other.





b. Using a feeler gauge, measure the clearance between the synchronizer ring and the input shaft spline.
Standard clearance: 1.05 to 1.85 mm (0.0413 to 0.0728 inch)
Minimum clearance: 0.80 mm (0.0315 inch)
If the clearance is less than the minimum, replace the synchronizer ring.





53. INSPECT PLANETARY PINION GEAR THRUST CLEARANCE
a. Using a feeler gauge, measure the thrust clearance of the planetary pinion gear.
Standard clearance: 0.11 to 0.84 mm (0.0043 to 0.0331 inch)
Maximum clearance: 0.84 mm (0.0331 inch)
If the clearance exceeds the maximum, replace the planetary gear assy.





54. INSPECT PLANETARY PINION GEAR RADIAL CLEARANCE
a. Using a dial indicator, measure the radial clearance of the planetary pinion gear.
Standard clearance: 0.009 to 0.038 mm (0.0004 to 00015 inch)
Maximum clearance: 0.038 mm (0.0015 inch)
If the clearance exceeds the maximum, replace the planetary gear assy.





55. REMOVE TRANSFER INPUT SHAFT BEARING
a. Using a snap ring expander, remove the input bearing shaft snap ring.
b. Using SST and a press, remove the input shaft bearing.
SST 09554-30011, 09555-55010





56. REMOVE TRANSFER LOW PLANETARY GEAR BEARING
a. Using SST, remove the low planetary gear bearing.
SST 09612-65014 (09612-01030, 09612-01050)

NOTICE: Hang SST securely to the clearance between the bearing and the low planetary gear.





57. INSPECT DRIVE SPROCKET THRUST CLEARANCE
a. Using a feeler gauge, measure the drive sprocket thrust clearance.
Standard clearance: 0.10 to 0.25 mm (0.0039 to 0.0098 inch)
Maximum clearance: 0.25 mm (0.0098 inch)
If the clearance exceeds the maximum, replace the drive sprocket.





58. REMOVE TRANSFER CLUTCH HUB
a. Using a snap ring expander, remove the clutch hub shaft snap ring.
b. Remove the high and low clutch sleeve.





c. Using a press, remove the clutch hub.





59. REMOVE TRANSFER OUTPUT SHAFT REAR RADIAL BALL BEARING
a. Using SST and a press, remove the bearing.
SST 09555-55010





60. REMOVE TRANSFER DRIVE SPROCKET SUB-ASSY
a. Remove the output shaft spacer and output shaft spacer ball.
b. Remove the drive sprocket sub-assembly, synchronizer inner ring, center ring, outer ring and drive clutch sleeve together.
c. Remove the drive sprocket bearing.
d. Remove the synchronizer inner ring, center ring, outer ring and drive clutch sleeve.
e. Remove the 3 synchromesh shifting keys No.1 and the 2 synchromesh shifting key springs No.1.





61. INSPECT TRANSFER OUTPUT SHAFT RR
a. Using a micrometer, measure the outer diameter of the output shaft rear journal surface.
Minimum diameter:
27.98 mm (1.1016 inch) for part A
36.98 mm (1.4561 inch) for part B
If the outer diameter is less than the minimum, replace the output shaft rear.





62. INSPECT DRIVE SPROCKET RADIAL CLEARANCE
a. Using a dial indicator, measure the radial clearance between the sprocket and the shaft with the needle roller bearing installed.
Standard clearance: 0.010 to 0.055 mm (0.0004 to 0.0022 inch)
Maximum clearance: 0.055 mm (0.0022 inch)
If the clearance exceeds the maximum, replace the drive sprocket, rear output shaft and drive sprocket bearing.





63. INSPECT GEAR SHIFT FORK AND HUB SLEEVE CLEARANCE
a. Using a feeler gauge, measure the clearance between the gear shift fork No.1 and drive clutch sleeve.
Maximum clearance: 1.0 mm (0.039 inch)
If the clearance exceeds the maximum, replace the gear shift fork No.1 and drive clutch sleeve.





64. INSPECT GEAR SHIFT FORK AND HUB SLEEVE CLEARANCE
a. Using a feeler gauge, measure the clearance between the gear shift fork No.2 and high and low clutch sleeve.
Maximum clearance: 1.0 mm (0.039 inch)
If the clearance exceeds the maximum, replace the gear shift fork No.2 and high and low clutch sleeve.





65. INSTALL FRONT DRIVE CLUTCH SLEEVE
a. Install the drive clutch sleeve onto the rear output shaft.

NOTICE: Make sure that the clutch sleeve is installed facing in the correct direction.





b. Install the 3 synchromesh shifting keys No.1 and the 2 synchromesh shifting keys spring No.1.

NOTICE: Install the key springs so that their end gaps are not in line.





66. INSTALL TRANSFER SYNCHRONIZER RING SET
a. Install the synchronizer outer ring onto the rear output shaft.

NOTICE: Align the slots of the synchronizer outer ring with the shifting keys.

b. Install the synchronizer center and the inner rings onto the rear output shaft.

NOTICE: Align the slots of the synchronizer outer with those of the inner rings.





67. INSTALL TRANSFER DRIVE SPROCKET SUB-ASSY
a. Install a new drive sprocket bearing.
b. Install the drive sprocket sub-assembly.

NOTICE: Align the holes in the drive sprocket with the protrusions on the synchronizer center ring.

c. Install the output shaft spacer aligned it with the output shaft spacer ball.