RM38N0EC _52 Drivetrain _119335 GF1A TRANSFER / 4WD / AWD _0524095 TRANSFER ASSEMBLY A

GF1A TRANSFER / 4WD / AWD TRANSFER ASSEMBLY DISASSEMBLY

CAUTION / NOTICE / HINT

NOTICE:: 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 O-rings, oil seals or rubber parts.

PROCEDURE

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

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

Hide Display 36100 2.SECURE TRANSFER ASSEMBLY

Secure the transfer assembly to the overhaul attachment.

Hide Display 36111G 3.REMOVE TRANSFER CASE STRAIGHT PIN

Remove the 2 transfer case straight pins.

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

Remove the No. 1 transfer case plug and gasket.

Hide Display 36114F 5.REMOVE TRANSFER DRAIN PLUG

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

Hide Display 36114L 6.REMOVE TRANSFER FILLER PLUG

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

Hide Display 36111H 7.REMOVE TRANSFER CASE BREATHER PLUG

Using a chisel and hammer, slightly pry out the transfer case breather plug.

Using a screwdriver, lightly pry up and remove the transfer case breather plug.

Hide Display 36111B 8.REMOVE TRANSFER CASE OIL SEAL

Click hereDrivetrain>GF1A (TRANSFER / 4WD / AWD)>TRANSFER CASE FRONT OIL SEAL (for LH Side)>REPLACEMENT202203,202303,_52,_119335,_0524093,RM1000000021Z66_01_0008,202303,202406,_52,_119335,_0524093,RM100000002AZ1R_01_0008,202406,202409,_52,_119335,_0524093,RM100000002MPTL_01_0008,202409,999999,_52,_119335,_0524093,RM100000002OMK2_01_0008,

Hide Display 36113D 9.REMOVE TRANSFER CASE OIL SEAL RH

2.5,1.521 2.333,1.521 2.333,1.521 2.167,0.938 true 0.5,0.667 0.583,0.667 0.583,0.667 0.75,0.417 true 2.615,1.438 3.073,1.635 0.458,0.198 10 false SST 0.25,0.563 0.479,0.76 0.229,0.198 10 true *1

*1	Transfer Case Oil Seal RH

Using SST, remove the transfer case oil seal RH from the No. 1 transfer case cover.

SST: 09308-00010

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

Hide Display 10.INSPECT TOTAL PRELOAD

1.688,1.417 2.021,1.417 true 2.188,0.458 2.5,0.656 0.313,0.198 10 false *a 2.073,1.333 2.385,1.531 0.313,0.198 10 false *b

*a	Torque Wrench Fulcrum Length
*b	Double Nut

Install the double nut to the rear transfer output shaft sub-assembly stud bolt and set the torque wrench into place.

HINT:: Adjust the double nut until the torque wrench is straight.

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

Torque:: Total preload (starting torque) : 0.87 to 2.85 N*m (8.88 to 29.06 kgf*cm, 7.71 to 25.22 in.*lbf)

HINT:

0.875,0.135 1.094,0.323 0.219,0.188 10 false L1 1.823,0.125 2.042,0.313 0.219,0.188 10 false L2

When using a torque wrench after changing its effective length, determine the reading of the torque wrench.

Formula T'=T x L2/(L1+L2)
T'	Reading of torque wrench (Nm (kgfcm, ft.*lbf))
T	Driven pinion preload (Nm (kgfcm, ft.*lbf))
L1	Distance from center of rear transfer output shaft sub-assembly to center of stud bolt (cm (in.))
L2	Length of torque wrench (cm (in.))

Distance from center of rear transfer output shaft sub-assembly to center of stud bolt (effective length of 38.9 mm (1.53 in.)) when using a torque wrench (effective length of 160 mm (6.30 in.)): 0.70 to 2.29 N*m (8 to 23 kgf*cm, 7 to 20 in.*lbf)

Hide Display 11.INSPECT RING GEAR BACKLASH

Insert a dial indicator through the transfer filler plug hole, and set it perpendicular to the edge of a ring gear tooth.

If the backlash is not within the specified range, adjust the backlash or repair as necessary.

While securing the rear transfer output shaft sub-assembly by hand, rotate the transfer ring gear mounting case forward and backward by hand and measure the backlash of the ring gear and driven pinion.

Standard Backlash:: 0.10 to 0.20 mm (0.00394 to 0.00787 in.)

NOTICE:: Measure the ring gear at 3 or more locations.

Hide Display 36121 12.REMOVE NO. 1 TRANSFER CASE COVER

Remove the 8 bolts.

Using a brass bar and hammer, remove the No. 1 transfer case cover from the transfer case.

NOTICE:: ·

Put the brass bar against the rib of the No. 1 transfer case cover.

·

When removing the No. 1 transfer case cover, be careful not to scratch the installation surface.

HINT:: To prevent the No. 1 transfer case cover from falling, leave 2 of the bolts screwed in by 5 or 6 threads.

Hide Display 13.REMOVE TRANSFER RING GEAR

Remove the transfer ring gear from the transfer case.

Hide Display 36111G 14.REMOVE TRANSFER CASE STRAIGHT PIN

Remove the 2 transfer case straight pins from the transfer case.

Hide Display 15.INSPECT DRIVEN PINION PRELOAD

1.688,1.417 2.021,1.417 true 2.073,1.323 2.354,1.521 0.281,0.198 10 false *b 2.219,0.458 2.531,0.615 0.313,0.156 10 false *a

*a	Torque Wrench Fulcrum Length
*b	Double Nut

Install the double nut to the rear transfer output shaft sub-assembly stud bolt and set the torque wrench into place.

HINT:: Adjust the double nut until the torque wrench is straight.

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

Torque:: Driven pinion preload (starting torque) : 0.39 to 2.21 N*m (3.98 to 22.53 kgf*cm, 3.46 to 19.55 in.*lbf)

HINT:

0.875,0.135 1.094,0.323 0.219,0.188 10 false L1 1.823,0.125 2.042,0.313 0.219,0.188 10 false L2

When using a torque wrench after changing its effective length, determine the reading of the torque wrench.

Formula T'=T x L2/(L1+L2)
T'	Reading of torque wrench (Nm (kgfcm, ft.*lbf))
T	Driven pinion preload (Nm (kgfcm, ft.*lbf))
L1	Distance from center of rear transfer output shaft sub-assembly to center of stud bolt (cm (in.))
L2	Length of torque wrench (cm (in.))

Hide Display 36202 16.REMOVE REAR TRANSFER OUTPUT SHAFT SUB-ASSEMBLY

Remove the 5 bolts and rear transfer output shaft sub-assembly from the transfer case.

Mount the rear transfer output shaft sub-assembly in a vise between aluminum plates.

NOTICE:: Do not overtighten the vise.

1.094,1.094 1.219,1.094 1.219,1.094 1.406,0.896 false 0.802,1.042 1.26,1.24 0.458,0.198 10 SST

Using SST and a hammer, unstake the transfer gear nut.

SST: 09930-00010

NOTICE:: ·

Be sure to use SST with the tapered surface facing the shaft.

·

Do not grind the tip of SST with a grinder or other device.

·

Completely loosen the staked part of the transfer gear nut when removing it.

·

Do not damage the threads of the output shaft sub-assembly.

Using a 30 mm socket wrench, remove the transfer gear nut.

Hide Display 17.REMOVE TRANSFER DRIVEN PINION

2.313,0.479 2.458,0.479 2.458,0.479 2.76,0.844 true 2.74,1.01 2.458,0.479 true 2.51,1.052 2.448,0.479 true 1.917,0.448 2.26,0.615 0.344,0.167 10 SST

Using SST and a press, remove the transfer driven pinion from the rear transfer output shaft sub-assembly.

SST: 09950-00020
09950-60011  (09951-00240)
09950-70010  (09951-07100)

NOTICE:: Support the front transfer driven pinion bearing as shown in the illustration to avoid placing stress on the outer race.

Hide Display 33325A 18.REMOVE REAR TRANSFER OUTPUT SHAFT DUST DEFLECTOR

2.365,0.563 2.25,0.563 2.25,0.563 2,1.021 false 2.406,0.49 2.729,0.667 0.323,0.177 10 SST

Using SST and a press, remove the rear transfer output shaft dust deflector from the rear transfer output shaft sub-assembly.

SST: 09950-00020

Hide Display 41201K 19.REMOVE FRONT TRANSFER DRIVEN PINION BEARING

1.859,0.496 2.2,0.661 0.341,0.166 10 SST 2.26,0.599 2.724,0.599 false 2.26,0.599 2.595,1.064 false 2.26,0.599 2.326,1.035 false

Using SST and a press, remove the front transfer driven pinion bearing from the transfer driven pinion.

SST: 09950-00020
09950-60011  (09951-00410)
09950-70010  (09951-07100)

NOTICE:: Support the front transfer driven pinion bearing as shown in the illustration to avoid placing stress on the outer race.

Remove the O-ring from the front transfer driven pinion bearing.

Hide Display 36275E 20.REMOVE TRANSFER OUTPUT SHAFT WASHER

Remove the transfer output shaft washer from the transfer driven pinion.

Hide Display 41301H 21.REMOVE RING GEAR MOUNTING CASE BEARING RH

2.563,1.51 2.844,1.896 true 2.365,1.563 2.844,1.896 2.844,1.896 3.031,1.896 true 3.052,0.5 3.365,0.656 0.313,0.156 10 *a 1.531,1.021 1.844,1.177 0.313,0.156 10 *b 3.083,1.781 3.427,1.979 0.344,0.198 10 SST

*a	Turn
*b	Hold

Using SST, remove the ring gear mounting case bearing RH (inner race) from the transfer ring gear mounting case.

SST: 09950-40011 (09951-04010, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011)
09950-60011 (09951-00540)

NOTICE:: ·

Apply a lubricant to the threads and end of SST.

·

Do not deform the cage of the ring gear mounting case bearing RH (inner race) (when reusing the bearing).

·

Place identification marks on the left and right ring gear mounting case bearings to distinguish them (backside, teeth side). Then store them separately (when reusing the bearings).

2.156,0.979 2.531,0.979 false 0.573,0.688 0.573,1.469 0.573,1.469 0.854,1.469 true 0.927,1.198 0.75,1.198 0.75,1.198 0.75,0.594 true 0.958,1.104 1.229,1.281 0.271,0.177 10 *1 0.896,1.385 1.167,1.542 0.271,0.156 10 *2 2.552,0.906 3.063,1.219 0.51,0.313 10 SST

*1	No. 2 Transfer Ring Gear Mounting Case Washer
*2	Ring Gear Mounting Case Bearing RH (Outer Race)

Using SST and a hammer, remove the No. 2 transfer ring gear mounting case washer and ring gear mounting case bearing RH (outer race) from the No. 1 transfer case cover.

SST: 09310-35010

Hide Display 41301H 22.REMOVE RING GEAR MOUNTING CASE BEARING LH

0.583,1.729 0.719,1.729 0.719,1.729 0.969,1.552 true 1.042,1.167 0.698,1.729 true 0.229,1.625 0.688,1.823 0.458,0.198 10 SST 2.76,0.271 3.073,0.427 0.313,0.156 10 *a 0.365,0.76 0.677,0.917 0.313,0.156 10 *b

*a	Turn
*b	Hold

Using SST, remove the ring gear mounting case bearing LH (inner race) from the transfer ring gear mounting case.

SST: 09950-00020
09950-00030

NOTICE:: ·

Apply a lubricant to the threads and end of SST.

·

Do not deform the cage of the ring gear mounting case bearing LH (inner race) (when reusing the bearing).

·

Place identification marks on the left and right ring gear mounting case bearings to distinguish them (backside, teeth side). Then store them separately (when reusing the bearings).

1.333,1.865 1.167,1.865 1.167,1.865 1.167,0.969 true 0.646,1.656 0.479,1.656 0.479,1.656 0.479,1.083 true 2.865,1.885 2.719,1.885 2.719,1.885 2.115,1.115 true 1.385,1.802 1.698,1.958 0.313,0.156 10 false *1 0.698,1.563 1.01,1.719 0.313,0.156 10 false *2 2.917,1.792 3.271,2.021 0.354,0.229 10 false SST

*1	No. 1 Ring Gear Mounting Case Washer
*2	Ring Gear Mounting Case Bearing LH (Outer Race)

Using SST and a hammer, remove the No. 1 ring gear mounting case washer and ring gear mounting case bearing LH (outer race) from the transfer case.

SST: 09636-20010

Hide Display 36212L 23.REMOVE SHAFT SNAP RING

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

Hide Display 41319 24.REMOVE TRANSFER RING GEAR MOUNTING CASE

1.906,0.406 2.115,0.406 false 2.135,0.333 2.615,0.563 0.479,0.229 10 SST

Using SST and a press, remove the transfer ring gear mounting case from the transfer ring gear.

SST: 09950-60011 (09951-00400)

Hide Display 36128B 25.REMOVE BREATHER OIL DEFLECTOR

Remove the 2 bolts and breather oil deflector from the transfer case.