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Transfer
Transfer
SECTION TF
CONTENTS
PREPARATION................................................................1 Shift Control Components .........................................12
Special Service Tools ..................................................1 DISASSEMBLY..............................................................13
Commercial Service Tools ...........................................2 REPAIR FOR COMPONENT PARTS............................19
NOISE, VIBRATION AND HARSHNESS (NVH) Mainshaft ...................................................................19
TROUBLESHOOTING .....................................................3 Front Drive Shaft .......................................................20
NVH Troubleshooting Chart.........................................3 Counter Gear .............................................................21
DESCRIPTION .................................................................4 Main Gear ..................................................................22
TF
Cross-sectional View ...................................................4 Front Case .................................................................24
ON-VEHICLE SERVICE ..................................................5 Front Case Cover ......................................................24
Replacing Oil Seal .......................................................5 Center Case...............................................................24
Checking Position Switch ............................................7 Bearing Retainer........................................................25
REMOVAL AND INSTALLATION ....................................8 Rear Case..................................................................25
Removal.......................................................................8 Shift Control Components .........................................26
Installation....................................................................8 ASSEMBLY....................................................................27
TRANSFER GEAR CONTROL .......................................9 SERVICE DATA AND SPECIFICATIONS (SDS) ..........33
MAJOR OVERHAUL .....................................................10 General Specifications...............................................33
Case Components .....................................................10 Inspection and Adjustment ........................................33
Gear Components .....................................................11
PREPARATION
NT428
ST30021000* Removing counter gear front bearing
Puller
NT411
ST30031000* Removing counter gear rear bearing
Puller
NT411
ST33290001* Removing center case oil seal
Puller Removing rear oil seal
NT414
ST22452000* Installing mainshaft rear bearing
Drift
TF-1
PREPARATION
TF-2
Symptom
TRANSFER
Reference page
Noise
Fluid leakage
1
3
2
FLUID (Wrong)
‘‘CHASSIS AND BODY MAINTENANCE’’).
1
1
FLUID (Level too high)
TF-3
2
LIQUID GASKET (Damaged) TF-10
2
OIL SEAL (Worn or damaged) TF-10
1
CHECK SPRING AND CHECK BALL (Worn or damaged) TF-10, TF-12
NVH Troubleshooting Chart
2
SHIFT FORK (Worn) TF-12
2
3
GEAR (Worn or damaged) TF-11
3
BEARING (Worn or damaged) TF-11
2
BAULK RING (Worn or damaged) TF-11
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
2
SHIFTING INSERT (Damaged) TF-11
Use the chart below to help you find the cause of the problem. The numbers indicate the order of the inspec-
DESCRIPTION
Cross-sectional View
SMT248D
TF-4
ON-VEHICLE SERVICE
SMT091B
SMT092B
SMT093B
SMT094B
SMT251D
TF-5
ON-VEHICLE SERVICE
Replacing Oil Seal (Cont’d)
2. Remove shift shaft oil seal.
+ Be careful not to damage inner shift lever.
SMT097B
SMT096B
SMT323B
SMT324B
SMT325B
TF-6
ON-VEHICLE SERVICE
SMT252D
SMT253D
TF-7
REMOVAL AND INSTALLATION
Removal
1. Drain fluid and oil from transfer and transmission (M/T model
only).
2. Remove exhaust front and rear tubes. Refer to FE section
(‘‘EXHAUST SYSTEM’’).
3. Remove front and rear propeller shaft. Refer to PD section
(‘‘Removal and Installation’’, ‘‘PROPELLER SHAFT’’).
4. Disconnect neutral position switch and 4WD switch harness
connectors.
5. Remove transfer control lever from transfer cross shaft.
SMT251D 6. Remove transfer from transmission.
WARNING:
Support transfer while removing it.
SMT268D
Installation
+ Apply recommended sealant to mating surface to transmission.
(M/T models only)
Recommended sealant:
Genuine anaerobic liquid gasket, Three Bond
TB1215, Loctite Part No. 51813 or equivalent
+ Tighten transfer bolts.
Transfer fixing bolts:
: 32 - 42 Nzm (3.3 - 4.3 kg-m, 24 - 31 ft-lb)
SMT176BA
TF-8
TRANSFER GEAR CONTROL
SMT254D
TF-9
MAJOR OVERHAUL
Case Components
SMT255D
TF-10
MAJOR OVERHAUL
Gear Components
SMT256D
TF-11
MAJOR OVERHAUL
SMT257D
TF-12
DISASSEMBLY
SMT101B
SMT258D
SMT103B
SMT104B
SMT105B
TF-13
DISASSEMBLY
SMT106B
SMT107B
SMT108B
SMT110B
TF-14
DISASSEMBLY
SMT111B
SMT112B
11. Remove front drive shaft assembly, drive chain and front drive
sprocket by tapping front end of front drive shaft.
SMT113B
12. Remove bolts securing bearing retainer and then remove bear-
ing retainer.
SMT115B
TF-15
DISASSEMBLY
13. Remove bolts securing center case to front case and then
separate center case and front case.
SMT116B
SMT117B
SMT118B
SMT119B
SMT120B
TF-16
DISASSEMBLY
SMT259D
SMT122B
c. Remove L & H shift rod and fork assembly with coupling sleeve.
SMT260D
SMT124B
e. Remove bolts securing front case cover and then remove it.
SMT125B
TF-17
DISASSEMBLY
SMT261D
SMT262D
TF-18
REPAIR FOR COMPONENT PARTS
Mainshaft
DISASSEMBLY
1. Remove snap ring and spacer.
SMT129B
SMT130B
INSPECTION
Gear and shaft
+ Check gears for excessive wear, chips or cracks.
+ Check shaft for cracks, wear or bending.
+ Check coupling sleeve for wear or damage.
SMT180B
Baulk ring
+ Check baulk ring for cracks or deformation.
SMT349A
SMT350A
TF-19
REPAIR FOR COMPONENT PARTS
Mainshaft (Cont’d)
Bearing
+ Make sure bearings roll freely and are free from noise, crack,
pitting or wear.
SMT351A
ASSEMBLY
1. Press mainshaft front bearing onto mainshaft.
+ Pay special attention to its direction.
SMT294A
2. Install spacer.
3. Select mainshaft front bearing snap ring with proper thickness
and install it.
Allowable clearance between mainshaft front bearing
snap ring and groove:
0 - 0.15 mm (0 - 0.0059 in)
Mainshaft front bearing snap ring:
Refer to SDS, TF-33.
SMT295A
SMT296A
SMT297A
TF-20
REPAIR FOR COMPONENT PARTS
Front Drive Shaft (Cont’d)
INSPECTION
Sprocket and shaft
+ Check sprocket for excessive wear, chips or cracks.
+ Check shaft for cracks or wear.
Bearing
+ Make sure bearings roll freely and are free from noise, crack,
pitting or wear.
SMT357A
ASSEMBLY
+ Press front drive shaft front bearing.
SMT298A
SMT299A
Counter Gear
DISASSEMBLY
1. Press out counter gear front bearing and then remove front
sub-gear, spacer and dish spring.
SMT134B
2. Press out counter gear rear bearing and then remove rear
sub-gear, spacer and dish spring.
SMT135B
TF-21
REPAIR FOR COMPONENT PARTS
Counter Gear (Cont’d)
INSPECTION
Gear and shaft
+ Check gears for excessive wear, chips or cracks.
+ Check shaft for cracks or wear.
Bearing
+ Make sure bearings roll freely and are free from noise, crack,
pitting or wear.
SMT266D
ASSEMBLY
1. Press on counter gear rear bearing.
SMT267D
2. Install front sub-gear, dish spring and spacer, and then press on
counter gear front bearing.
+ Pay attention to direction of dish spring.
SMT137B
Main Gear
DISASSEMBLY
Main gear bearing
1. Remove snap ring and spacer.
SMT304A
SMT305AA
TF-22
REPAIR FOR COMPONENT PARTS
Main Gear (Cont’d)
Plug
+ Always replace it with new one whenever it is removed.
SMT306A
INSPECTION
Gear and shaft
+ Check gears for excessive wear, chips or cracks.
+ Check shaft for cracks or wear.
Bearing
+ Make sure bearings roll freely and are free from noise, crack,
pitting or wear.
SMT359A
ASSEMBLY
Main gear bearing
1. Press on main gear bearing.
+ Pay attention to its direction.
2. Install spacer.
SMT307AA
SMT308A
Plug
+ Apply sealant to plug and install it.
SMT309A
TF-23
REPAIR FOR COMPONENT PARTS
Front Case
SHIFT SHAFT OIL SEAL
Removal
+ Use a screwdriver to pry out old seal.
+ Be careful not to damage case.
+ Always replace with a new one whenever it has been removed.
SMT138B
Installation
+ Install new shift shaft oil seal until flush with case.
+ Before installing, apply multi-purpose grease to seal lip.
SMT139B
SMT263D
Installation
+ Install new front case cover oil seal until it stops.
+ Before installing, apply multi-purpose grease to seal lip.
SMT141B
Center Case
CENTER CASE OIL SEAL
Removal
+ Remove center case oil seal.
SMT146B
TF-24
REPAIR FOR COMPONENT PARTS
Installation
+ Install center case oil seal.
SMT147B
Bearing Retainer
OIL CATCHER
Removal
+ Drive out oil catcher from inside of bearing retainer.
+ Be careful not to damage bearing retainer.
SMT142B
Installation
+ Install oil catcher until it stops.
+ Be careful not to damage or distort oil catcher or bearing
retainer.
+ Before installing, apply multi-purpose grease to seal lip.
SMT143B
Rear Case
REAR OIL SEAL
Removal
+ Pull out rear oil seal.
SMT144B
Installation
+ Install new rear oil seal until it stops.
+ Before installing, apply multi-purpose grease to seal lip.
SMT145B
TF-25
REPAIR FOR COMPONENT PARTS
AIR BREATHER
+ Install as shown in illustration.
Thread locker:
Refer to TF-10.
SMT148B
SMT360A
SMT149B
SMT150B
SMT033B
TF-26
ASSEMBLY
SMT151B
SMT152B
SMT153B
c. Apply gear oil to needle bearing and install it into main gear.
SMT326A
SMT264D
TF-27
ASSEMBLY
SMT090B
f. Install L & H shift rod and fork assembly with coupling sleeve.
SMT155B
SMT265D
SMT259D
SMT335A
TF-28
ASSEMBLY
SMT157B
SMT158B
SMT159B
SMT407A
SMT160B
TF-29
ASSEMBLY
SMT161B
SMT117B
SMT163B
SMT164B
SMT165B
TF-30
ASSEMBLY
c. Apply gear oil to needle bearings and install them into front
drive sprocket.
+ These needle bearings can be easily installed if front drive
sprocket is rotated during their installation.
SMT166B
SMT167B
SMT168B
SMT169B
SMT170B
TF-31
ASSEMBLY
SMT107B
SMT106B
SMT171B
TF-32
SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
Transfer model TX12A
High 1.000
Gear ratio
Low 2.020
Main gear 29
Low gear 37
Counter High 38
Number of teeth
gear Low 24
TF-33