NOTE: Refer to the Exploded View as needed during the following procedure.
1.
Transfer Hypoid Drive Gear/Shaft Assembly - Remove
1.
Remove the transfer hypoid drive gear/shaft assembly (A) and the dowel pin (B) with the O-ring (C).
2.
Transfer Driven Gear - Remove
1.
Cut the lock tab (A) on the locknut (B) of the transfer hypoid drive shaft using a chisel.
NOTE:
Be careful not to damage the shaft.
Make sure the tab completely clears the groove to prevent damaging the shaft.
2.
Secure the transfer hypoid drive gear/shaft assembly (A) in a bench vise (B) with hex wrench (C).
3.
Remove the locknut (D).
4.
Remove the transfer driven gear (A) and the thrust washer (B) using a puller (C).
3.
Companion Flange - Remove
1.
Cut the lock tab (A) on the locknut (B) of the transfer output shaft using a chisel.
NOTE:
Be careful not to damage the shaft.
Make sure the tab completely clears the groove to prevent damaging the shaft.
2.
Secure the transfer housing (A) in a bench vise (B).
NOTE: To prevent damaging the transfer housing, always use wood blocks or equivalent materials (C) between the transfer housing and the bench vise.
3.
Install the companion holder, then loosen the locknut.
4.
Remove the companion holder.
5.
Remove the locknut (A), the conical spring washer (B), the back-up ring (C), the O-ring (D), and the companion flange (E).
4.
Transfer Hypoid Driven Gear - Remove
1.
Remove the transfer hypoid driven gear (A) and the transfer spacer (B).
5.
Transfer Oil Seal - Remove
NOTE:
Apply a light coat of clean transmission fluid on all moving parts before reassembly.
Refer to the Exploded View as needed during the following procedure.
1.
Transfer Oil Seal - Install
1.
Install a new transfer oil seal (A) flush with the transfer housing surface (B) using the 15 x 135L driver handle and the 58 mm oil seal driver attachment.
NOTE: Apply a light coat of clean transmission fluid on oil seal before installation.
2.
Transfer Hypoid Driven Gear - Install
1.
Install the transfer hypoid driven gear (A) with a new transfer spacer (B).
NOTE: Install the transfer spacer in the direction shown.
3.
Companion Flange - Install
1.
Install the companion flange (A), a new O-ring (B), the back-up ring (C), a new conical spring washer (D), and a new locknut (E).
NOTE: Install the conical spring washer in the direction shown.
2.
Secure the transfer housing (A) in a bench vise (B).
NOTE: To prevent damaging the transfer housing, always use wood blocks or equivalent materials (C) between the transfer housing and the bench vise.
3.
Install the companion holder.
4.
Tighten the locknut while measuring the starting torque of the transfer output shaft (hypoid gear) so the starting torque is within 0.98?1.39 N·m (10.0?14.2 kgf·cm, 8.7?12.3 Ibf·in). Tighten the locknut to the lower torque specification, then check the starting torque. If the starting torque is low, increase the torque on the locknut until the starting torque is acceptable.
Tightening Torque:
132?260 N·m (13.5?26.5 kgf·m, 97?192 Ibf·ft)
Starting Torque:
0.98?1.39 N·m (10.0?14.2 kgf·cm, 8.7?12.3 Ibf·in)
NOTE:
Rotate the companion flange several times to seat the tapered roller bearings, then measure the starting torque.
If the starting torque exceeds 1.39 N·m (14.2 kgf·cm, 12.3 Ibf·in), replace the transfer spacer and reassemble the parts. Do not adjust the torque with the locknut loose.
If the tightening torque exceeds 260 N·m (26.5 kgf·m, 192 Ibf·ft), replace the transfer spacer and reassemble the parts.
5.
Remove the companion holder.
6.
Stake the locknut to a depth (A) of at least 0.7 mm (0.028 in) using a 3.0 - 3.5 mm (0.118 - 0.138 in) punch (B).
NOTE: Be careful not to crack the locknut when staking.
4.
Transfer Driven Gear - Install
1.
Install the transfer driven gear (A) using the 32.5 mm driver attachment.
NOTE: Install the transfer driven gear in the direction shown.
2.
Install a new thrust washer (A) using the 32.5 mm driver attachment.
NOTE: Install the thrust washer in the direction shown.
3.
Secure the transfer hypoid drive gear/shaft assembly (A) in a bench vise (B) with hex wrench (C).
4.
Install a new locknut (D).
5.
Stake the locknut to a depth (A) of at least 0.7 mm (0.028 in) using a 3.0 - 3.5 mm (0.118 - 0.138 in) (B).
NOTE: Be careful not to crack the locknut when staking.
6.
Secure the transfer hypoid drive gear/shaft assembly (A) in a bench vise (B).
NOTE: To prevent damaging the transfer hypoid drive gear/shaft assembly, always use wood blocks or equivalent materials (C) between the transfer hypoid drive gear/shaft assembly and the bench vise.
7.
Rotate the transfer driven gear (D) in both directions to seat the bearings.
8.
Measure the starting torque of the transfer hypoid drive gear/shaft assembly using the torque wrench (E), and a socket (F).
