Disassembly

GF1A TRANSFER: TRANSFER ASSEMBLY: DISASSEMBLY

DISASSEMBLY





1. REMOVE TRANSFER AND TRANSAXLE SETTING STUD BOLT
(a) Remove the stud bolt.






2. REMOVE TRANSFER CASE STRAIGHT PIN
(a) Remove the 2 straight pins.
3. REMOVE TRANSFER CASE NO. 1 PLUG
(a) Remove the No. 1 plug.
(b) Remove the gasket from the No. 1 plug.






4. REMOVE TRANSFER CASE NO. 2 PLUG
(a) Remove the No. 2 plug.
(b) Remove the gasket from the No. 2 plug.






5. REMOVE TRANSFER DRAIN PLUG
(a) Remove the drain plug.
(b) Remove the gasket from the drain plug.






6. REMOVE TRANSFER CASE OIL SEAL LH
(a) Using SST, tap out the oil seal from the case.
SST: 09308-00010
NOTE: Do not damage the oil seal lip.





7. REMOVE TRANSFER CASE OIL SEAL RH
(a) Using SST, tap out the oil seal from the case.
SST: 09308-00010
NOTE: Do not damage the oil seal lip.





8. INSPECT RING GEAR BACKLASH
(a) Using a dial indicator, measure the backlash of the ring gear at 3 points.
Standard backlash:
0.10 to 0.20 mm (0.0039 to 0.0079 in.)
If the backlash is not within the specified range, adjust the backlash or repair as necessary.
9. REMOVE NO. 1 TRANSFER CASE COVER






(a) Remove the 8 bolts.






(b) Using a brass bar and hammer, tap out the cover from the case.






10. REMOVE TRANSFER RING GEAR
(a) Remove the ring gear from the transfer case.
11. REMOVE TRANSFER CASE STRAIGHT PIN
(a) Remove the 2 straight pins from the transfer case.
12. REMOVE TRANSFER OUTPUT SHAFT





(a) Remove the 5 bolts and output shaft.






(b) Using SST and a hammer, unstake the lock nut.
SST: 09930-00010
(c) Remove the lock nut.






13. REMOVE TRANSFER OUTPUT REAR SHAFT SUB-ASSEMBLY
(a) Using SST and a press, press out the shaft from the driven pinion.
SST: 09950-00020
SST: 09950-60010
09951-00220
SST: 09950-70010
09951-07100
14. REMOVE TRANSFER DRIVEN PINION FRONT BEARING





(a) Using SST and a press, press out the driven pinion from the bearing.
SST: 09950-00020
SST: 09950-60010
09951-00220
SST: 09950-70010
09951-07100






(b) Remove the O-ring from the bearing.






15. REMOVE TRANSFER OUTPUT SHAFT WASHER
(a) Remove the washer from the transfer pinion gear.
16. REMOVE RING GEAR MOUNTING CASE BEARING (for LH side)





(a) Using SST, remove the bearing from the mounting case.
SST: 09950-40011
09951-04010
09952-04010
09953-04030
09954-04010
09955-04061
09957-04010
09958-04011
SST: 09950-60010
09951-00540






(b) Using SST and a hammer, tap out the bearing.
SST: 09310-35010
17. REMOVE RING GEAR MOUNTING CASE WASHER






18. REMOVE RING GEAR MOUNTING CASE BEARING (for RH side)
(a) Using SST, remove the bearing from the mounting case.
SST: 09950-40011
09951-04010
09952-04010
09953-04020
09954-04010
09955-04061
09957-04010
09958-04011
SST: 09950-60010
09951-00540
(b) Using SST and a hammer, tap out the bearing (race) from the cover.
SST: 09636-20010
19. REMOVE TRANSFER RING GEAR MOUNTING CASE NO. 2 WASHER






20. REMOVE SHAFT SNAP RING
(a) Using a snap ring expander, remove the snap ring.






21. REMOVE TRANSFER RING GEAR MOUNTING CASE
(a) Using SST and a press, press out the ring gear from the mounting case.
SST: 09950-60010
09951-00400






22. REMOVE BREATHER OIL DEFLECTOR
(a) Remove the 2 bolts and oil deflector.






23. REMOVE TRANSFER CASE BREATHER PLUG
(a) Remove the breather plug from the transfer case.