GF2A TRANSFER / 4WD / AWD  TRANSFER ASSEMBLY  REASSEMBLY  

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

Align the matchmark on the output shaft companion flange with the transfer gear groove, and then temporarily install the output shaft companion flange sub-assembly as shown in the illustration.

2.5,2.333 1.813,2.333 1.813,2.333 1.813,1.719 true 2.167,2.333 2.167,1.833 true 2.656,0.531 2.969,0.688 0.313,0.156 10 false *a 0.625,1.146 0.938,1.302 0.313,0.156 10 false *b 2.583,2.26 2.979,2.5 0.396,0.24 10 false SST

*a	Turn
*b	Hold

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

SST

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

0.802,2.125 0.802,1.792 true 2.938,1.25 3.25,1.406 0.313,0.156 10 false *a 0.594,1.396 0.906,1.552 0.313,0.156 10 false *b 0.719,2.177 1.281,2.427 0.563,0.25 10 false SST

*a	Turn
*b	Hold

Using SST, temporarily install the output shaft companion flange nut.

SST

09330-00021  

Torque:

140 N*m (1428 kgf*cm, 103 ft.*lbf)

CAUTION:

The total preload may be within the standard even when the output shaft companion flange is loose. If the output shaft companion flange is installed in this state, the vehicle may be damaged or lead to a serious accident.

NOTICE:

Tighten the output shaft companion flange nut until there is no more looseness in the output shaft companion flange and it turns to the right and left with the same amount of force.

NOTICE:

·

The total preload may be within the standard even when the output shaft companion flange is loose. If the output shaft companion flange is installed in this state, the vehicle may be damaged or lead to a serious accident.

·

Tighten the output shaft companion flange nut until there is no more looseness in the output shaft companion flange and it turns to the right and left with the same amount of force.

HINT:

After temporarily installing the output shaft companion flange nut, be sure to adjust the preoload.

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

HINT:

·

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

·

For a more accurate measurement, rotate the bearing forward and backward several times before the measurement.

·

Use the preload value measured prior to disassembling the transfer assembly as the standard value.

·

Adjust within the standard value (Adjustable range within +/- 0.2 N*m of the measured preload value).

1.583,1.063 1.813,0.615 1.813,0.615 1.979,0.615 true 2.135,1.229 2.281,1.698 2.281,1.698 2.448,1.698 true 2.552,1.625 2.969,1.896 0.417,0.271 10 false SST 2.052,0.531 2.365,0.688 0.313,0.156 10 false *a

*a

Matchmark

Place a matchmark on SST as shown in the illustration.

SST

09930-42010  

1.75,0.448 1.75,0.667 1.75,0.667 2.5,0.667 true 2.469,0.448 1.583,0.448 true 1.354,0.375 1.667,0.563 0.313,0.188 10 false *a

*a

Matchmark

Install SST aligned with the matchmark on the output shaft companion flange sub-assembly as shown in the illustration.

1.854,1.198 2.083,0.75 2.083,0.75 2.25,0.75 false 2.323,0.677 2.781,0.958 0.458,0.281 10 false SST

Using SST and a hammer, stake the output shaft companion flange nut.

NOTICE:

Check that the matchmarks are properly aligned.

2.021,2.646 2.5,2.083 true 1.958,2.25 2.5,2.083 2.5,2.083 2.667,2.083 true 1.99,0.99 1.823,0.99 1.823,0.99 1.49,0.677 true 2.74,2.01 3.167,2.25 0.427,0.24 10 false SST 2.083,0.917 2.417,1.167 0.333,0.25 10 false *1 1.906,0.292 2.24,0.542 0.333,0.25 10 false (A)

*1	Transfer Case Oil Seal RH

Using SST and a hammer, tap in a new transfer case oil seal RH as shown in the illustration.

SST

09223-46011  
09631-32020  

Drive in depth (A):

-0.5 to 0.5 mm (-0.0197 to 0.0196 in.)

NOTICE:

·

Tap the transfer case oil seal RH uniformly so that the transfer case oil seal RH is straight.

·

Do not tap the transfer case oil seal RH in too far.

Install a new transfer case breather plug to the transfer case.

Torque:

11.3 N*m (115 kgf*cm, 8 ft.*lbf)

2.135,0.552 2.417,0.167 2.417,0.167 2.5,0.167 true 2.583,0.104 3.042,0.302 0.458,0.198 10 false SST

Using SST, install the No. 1 4 wheel drive position switch to the transfer case.

SST

09816-30010  

Torque:

40.2 N*m (410 kgf*cm, 30 ft.*lbf)

3.031,0.802 3.313,1.052 0.281,0.25 10 false (A)

Using a plastic-faced hammer, install the 2 transfer case straight pins to the locations shown in the illustration.

Drive in depth (A):

10.8 to 11.8 mm (0.426 to 0.464 in.)

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

Torque:

39 N*m (398 kgf*cm, 29 ft.*lbf)

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

Torque:

39 N*m (398 kgf*cm, 29 ft.*lbf)

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

Torque:

39 N*m (398 kgf*cm, 29 ft.*lbf)

Install a new gasket and the No. 1 transfer case plug.

Torque:

49 N*m (500 kgf*cm, 36 ft.*lbf)

Remove the transfer assembly from the overhaul attachment.

2.167,1.667 2.333,1.667 2.333,1.667 2.583,1.417 true 1.906,1.583 2.125,1.844 0.219,0.26 10 false *a 3.094,1 3.406,1.156 0.313,0.156 10 false *b

*a	Adhesive 1324
*b	64 mm (2.520 in.)

Using 2 nuts, install 4 new stud bolts in the locations shown in the illustration.

Torque:

39.2 N*m (400 kgf*cm, 29 ft.*lbf)

NOTICE:

Install the shorter threaded part of each stud bolt to the transfer side.