RM36D0EC _52 Drivetrain _083068 GF2A TRANSFER / 4WD / AWD _0402926 TRANSFER ASSEMBLY A

GF2A TRANSFER / 4WD / AWD  TRANSFER ASSEMBLY  DISASSEMBLY  


CAUTION / NOTICE / HINT

NOTICE:
·

When replacing the rear drive pinion companion flange and rear transfer case oil seal, be sure to check the preload.

·

If the output shaft companion flange sub-assembly and rear transfer case oil seal were replaced without checking the preload, replace the transfer assembly.

·

Before installation of each part, thoroughly clean and dry it. Then apply grease or oil as necessary. Do not use alkaline chemicals to clean aluminum parts, rubber parts or precoated bolts. Also, do not use non-residue solvent or other cleaning oils to clean oil seals or rubber parts.



PROCEDURE

Hide 36100A 1.REMOVE TRANSFER AND TRANSAXLE SETTING STUD BOLT

a.
C407463

Using 2 nuts, remove the 4 transfer and transaxle setting stud bolts.


Hide 36100 2.SECURE TRANSFER ASSEMBLY

C407464

a.

Secure the transfer assembly to the overhaul attachment.


Hide 36111G 3.REMOVE TRANSFER CASE STRAIGHT PIN

C407465

a.

Remove the 2 transfer case straight pins.


Hide 36114B 4.REMOVE NO. 1 TRANSFER CASE PLUG

C407520

a.

Remove the No. 1 transfer case plug and gasket.


Hide 36114F 5.REMOVE TRANSFER DRAIN PLUG

C407466

a.

Using a 10 mm socket hexagon wrench, remove the transfer drain plug and gasket.


Hide 36114L 6.REMOVE TRANSFER FILLER PLUG

C407467

a.

Using a 10 mm socket hexagon wrench, remove the transfer filler plug and gasket.


Hide 36114H 7.REMOVE NO. 2 TRANSFER CASE PLUG

a.
C427093

Using a 10 mm socket hexagon wrench, remove the No. 2 transfer case plug and gasket.


Hide 84546 8.REMOVE NO. 1 4 WHEEL DRIVE POSITION SWITCH

a.
C407462

Remove the No. 1 4 wheel drive position switch.


Hide 36111H 9.REMOVE TRANSFER CASE BREATHER PLUG

a.
C407468

Remove the transfer case breather plug.


Hide 36113D 11.REMOVE TRANSFER CASE OIL SEAL RH

a.
C405123C01
0.417,0.667 0.5,0.667 0.5,0.667 0.729,0.333 true 2.177,1.448 2.177,0.948 true 0.25,0.594 0.563,0.75 0.313,0.156 10 false *1 2.052,1.5 2.438,1.688 0.385,0.188 10 false SST
*1 Transfer Case Oil Seal RH


Using SST, remove the transfer case oil seal RH from the electromagnetic control clutch sub-assembly.

SST
09308-00010  

NOTICE:

Do not scratch the press-fitting surface of the transfer case oil seal RH.



Hide 12.INSPECT TOTAL PRELOAD

NOTICE:
·

When replacing the output shaft companion flange and No. 2 transfer case oil seal, be sure to check the preload.

·

If the output shaft companion flange and No. 2 transfer case oil seal were replaced without checking the preload, replace the transfer assembly.



a.
C420575

Using a torque wrench, check the starting torque (total preload) with the teeth of the driven pinion and ring gear in contact.

HINT:
·

The torque wrench should be installed as shown in the illustration.

·

Record the measured value as it is used during assembly.




Hide 13.REMOVE OUTPUT SHAFT COMPANION FLANGE NUT

a.
C407515C01
1.688,0.75 2,0.406 2,0.406 2.167,0.406 true 2.25,0.313 2.479,0.51 0.229,0.198 10 true *a
*a Matchmark


Place a matchmark on the output shaft companion flange sub-assembly as shown in the illustration.

HINT:

Place a matchmark aligned with the groove on the transfer gear.



b.
C407513

Using a screwdriver and hammer, unstake the output shaft companion flange nut.

NOTICE:
·

Completely unstake the output shaft companion flange nut.

·

Do not damage the threads of the transfer gear.




Hide 33309B 14.REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY

a.
C420576C01
1.802,1.729 1.802,2.333 1.802,2.333 2.469,2.333 true 2.125,1.833 2.125,2.333 true 2.521,1 2.833,1.156 0.313,0.156 10 false *a 0.854,0.51 1.167,0.667 0.313,0.156 10 false *b 2.542,2.271 2.958,2.604 0.417,0.333 10 false SST
*a Turn
*b Hold


Using SST, remove the output shaft companion flange sub-assembly.

SST
09950-30012  (09951-03010, 09953-03010, 09954-03010, 09955-03030)
09956-03090