1. Install the center differential and transfer driven gear into the transfer case.
2. Remove the bearing outer race from the extension case.
|
(A) |
Bearing outer race |
|
(B) |
Extension case |
3. While pressing the bearing outer race horizontally, rotate the driven shaft for ten turns.
4. Measure the height “W” between transfer case and taper roller bearing on the transfer driven gear.
5. Measure the depth “X”.
NOTE:
Measure with the bearing outer race mounted and the thrust washer removed.
6. Calculate the thrust washer thickness “t” using following calculation. t = X − W + (0.2 — 0.3 mm (0.008 — 0.012 in))
7. Select the washer with the nearest value in the following table.
Taper roller bearing preload (standard protrusion amount):
0.2 — 0.3 mm (0.008 — 0.012 in)
NOTE:
Be sure that the preload is always within the standard.
|
Thrust washer (50 × 61 × t) | |
|
Part number |
Thickness mm (in) |
|
803050060 |
0.50 (0.0197) |
|
803050061 |
0.55 (0.0217) |
|
803050062 |
0.60 (0.0236) |
|
803050063 |
0.65 (0.0256) |
|
803050064 |
0.70 (0.0276) |
|
803050065 |
0.75 (0.0295) |
|
803050066 |
0.80 (0.0315) |
|
803050067 |
0.85 (0.0335) |
|
803050068 |
0.90 (0.0354) |
|
803050069 |
0.95 (0.0374) |
|
803050070 |
1.00 (0.0394) |
|
803050071 |
1.05 (0.0413) |
|
803050072 |
1.10 (0.0433) |
|
803050073 |
1.15 (0.0453) |
|
803050074 |
1.20 (0.0472) |
|
803050075 |
1.25 (0.0492) |
|
803050076 |
1.30 (0.0512) |
|
803050077 |
1.35 (0.0531) |
|
803050078 |
1.40 (0.0551) |
|
803050079 |
1.45 (0.0571) |
8. Fit the thrust washers on the transfer drive shaft.
9. Install the bearing outer race into the extension case.
10. Measure the depth “S” between transfer case and center differential.
| ST 398643600 | GAUGE |
11. Measure the depth “T” between extension case and transfer drive gear.
| ST 398643600 | GAUGE |
NOTE:
ST thickness [15 mm (0.59 in)]
12. Calculate the thrust washer “U” using following calculation.
U = S + T − 30 mm (1.18 in) [Thickness of ST]
13. Select a suitable washer in the following table.
Standard clearance
0.15 — 0.35 mm (0.0059 — 0.0138 in)
|
Thrust washer | |
|
Part number |
Thickness mm (in) |
|
803036050 |
0.9 (0.035) |
|
803036054 |
1.0 (0.039) |
|
803036051 |
1.1 (0.043) |
|
803036055 |
1.2 (0.047) |
|
803036052 |
1.3 (0.051) |
|
803036056 |
1.4 (0.055) |
|
803036053 |
1.5 (0.059) |
|
803036057 |
1.6 (0.063) |
|
803036058 |
1.7 (0.067) |
14. Fit the thrust washer onto the center differential.
15. Apply a proper amount of liquid gasket to the transfer case mating surface.
Liquid gasket
THREE BOND 1215 (Part No. 004403007) or equivalent
16. Install the extension assembly into the transfer case.
Tightening torque:
40 N·m (4.1 kgf-m, 30 ft-lb)
17. Attach the shifter arm to transfer case.
18. Hang the shifter arm on 3rd-4th fork rod.
|
(A) |
Shifter arm |
|
(B) |
3rd-4th fork rod |
19. Install the extension case assembly along with the transfer case to the transmission case.
Tightening torque:
24.5 N·m (2.5 kgf-m, 18.1 ft-lb)
