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 holding 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 depth “X” on bearing insertion part of the extension case.
NOTE:
Measure with bearing outer race and thrust washer removed.
6. Calculate the thrust washer thickness “t” using the following calculation.
t = X − W + (0.15 — 0.20 mm (0.006 — 0.008 in))
7. Select the washer with the nearest value in the following table.
Preload of the taper roller bearing (amount of standard protrusion):
0.15 — 0.20 mm (0.006 — 0.008 in)
NOTE:
Be sure that the amount of preload is within the standard value.
|
Thrust washer (50 × 61 × t) | |
|
Part No. |
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 thickness “U” of the thrust washer 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 No. |
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 to the transfer case.
Tightening torque:
40 N·m (4.1 kgf-m, 29.5 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)
