Transfer Clutch

Transfer Clutch

REMOVAL
1) Remove the transmission assembly from the vehicle.





2) Remove the rear vehicle speed sensor.





3) Separate transmission case and extension case sections.





4) Take out the transfer clutch by lightly tapping the end of the rear drive shaft.

INSTALLATION
1) Select the thrust needle bearing.





2) Install the transfer clutch assembly to the case.





3) Tighten bolts to secure the case.
Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft. lbs.)
4) Install the transmission assembly to the vehicle.

DISASSEMBLY





1) Remove the seal ring.





2) Using a press and ST, remove the ball bearing.
ST 498077600 REMOVER





3) Remove the snap ring, and take out the pressure plate, drive plates, and driven plates.





4) Remove the snap ring with ST1, ST2 and ST3, and take out the return spring and transfer clutch piston seal.
ST1 399893600 PLIERS
ST2 398673600 COMPRESSOR
ST3 398623600 SEAT





5) Apply compressed air to the rear drive shaft to remove the piston.

ASSEMBLY





1) Install the transfer clutch piston.





2) Install return spring to transfer piston.





3) Install transfer clutch piston seal.





4) Install ST to rear drive shaft.
ST 499257300 SNAP RING OUTER GUIDE





5) Install snap ring to ST.
ST 499257300 SNAP RING OUTER GUIDE





6) Using ST1 and ST2, install snap ring to rear drive shaft.
ST1 499257300 SNAP RING OUTER GUIDE
ST2 499247400 INSTALLER





7) Install the driven plates, drive plates, pressure plate and snap ring.





8) Apply compressed air to see if the assembled parts move smoothly.
9) Inspect clearance between snap ring and pressure plate.





10) Press-fit a new ball bearing with ST.
ST 899580100 INSTALLER





11) Coat a new seal ring with petrolatum, and install it in the seal ring groove of the shaft.

NOTE: Do not expand the seal ring excessively when installing.





12)Install the transfer clutch assembly without damaging seal ring.

INSPECTION
^ Check the drive plate facing for wear and damage.
^ Check the snap ring for wear, and the return spring for permanent set, breakage and deformation.
^ Check the D ring for damage.
^ Measure the extension end play and adjust it to within specifications.

1) Inspect clearance between snap ring and pressure plate.
2) Before measuring clearance, place the same thickness of shim on both sides to prevent pressure plate from tilting.








3) If the clearance is not within specification, adjust it by selecting a suitable pressure plate on the transfer clutch piston side.
Standard: 0.7 - 1.1 mm (0.028 - 0.043 inch)
Service limit: 1.6 mm (0.063 inch)
4) Check if tight corner braking does not occur when the vehicle is started with steering wheel held at fully turned position. If tight corner braking occurs, perform the following procedures.
1) With the steering wheel held at fully turned position, drive the vehicle in "D" range and with vehicle speed at approximately 5 km/h (3 mph) in both clockwise and counterclockwise directions for approximately ten times each, while repeating acceleration and braking intermittently.
2) If the tight corner braking still persists, drive the vehicle again in a circle for several laps.

ADJUSTMENT
MPT MODEL





1) Measure distance "L" from end of extension case and rear drive shaft with ST. ST 398643600 GAUGE L = Measured value - 15 mm (L = Measured value - 0.59 inch)





A: Measured value
B: ST thickness [15 mm (0.59 inch)]
L: Distance from end of extension case to end of rear drive shaft
2) Measure the distance " l " from the transmission case mating surface to the reduction drive gear end surface with ST1 and ST2.
l = Measured value - 50 mm
l = Measured value - 1.97 inch)
ST1 398643600 GAUGE
ST2 499577000 GAUGE
A: Measured value
B: ST thickness [50 mm (1.97 inch)]
l: Distance from end of transmission case to end of reduction drive gear
3) Calculation equation:

NOTE:
Calculating H:
When clearance is at 0.05 mm (0.0020 inch) and 0.25 mm (0.0098 inch), then select a suitable thrust needle bearing from the table.
H = (L + 0.45mm)- l -T
[H = (L + 0.0177 inch) - l - T]
T: Thrust needle bearing thickness
L: Distance from end of extension case to end of rear drive shaft 0.45 mm (0.0177 inch): Gasket thickness
l: Distance from end of transmission case to end of reduction drive gear
H: Shim clearance 0.05 - 0.25 mm (0.0020 - 0.0098 inch)
Example:
When, L = 18.60 mm (0.7323 inch), l = 15.05 mm (0.5925 inch)
Calculation when clearance is 0.05 mm (0.0020 inch)
H = (18.60 + 0.45) - 15.05 - 0.05 = 3.95
[H = (0.7323 + 0.0177) - 0.5925 - 0.0020 = 0.1555]
Calculation when clearance is 0.25 mm (0.0098 inch)
H = (18.60 + 0.45) - 15.05 - 0.25 = 3.75
[H = (0.7323 + 0.0177) - 0.5925 - 0.0098 = 0.1476]





After calculation, the value of H becomes between 3.75 and 3.95, therefore select bearing thickness of 3.8.

VTD MODEL





1) Insert the rear drive shaft into the reduction drive gear and center differential assembly.





2) Measure distance L from extension case mating surface to multi-plate clutch (LSD) piston with ST.
ST 398643600 GAUGE L = Measured value - 15 mm (L = Measured value - 0.59 inch)
A: Measured value
B: ST thickness [15 mm (0.59 inch)]
L: Distance from end of extension case to end of rear drive shaft





3) Measure the distance " l " from the transmission case mating surface to the reduction drive gear end surface with ST.
Q = Measured value - 15 mm (Q = Measured value - 0.59 inch)
ST 398643600 GAUGE
A: Measured value
B: ST thickness [15 mm (0.59 inch)]
l: Distance from end of extension case to end of reduction drive gear
4) Calculation equation:

NOTE:
Calculating H:
When clearance is at 0.05 mm (0.0020 inch) and 0.25 mm (0.0098 inch), then select up to 4 shims from the table so that their total thickness matches the clearance.
H = (L + 0.45 mm) - l -T
[H = (L + 0.0177 inch) - l - T]
T: Shim clearance
L: Distance from end of extension case to end of rear drive shaft 0.45 mm (0.0177 inch):Gasket thickness
a: Distance from end of transmission case to end of reduction drive gear
T: Shim thickness 0.05 - 0.25 mm (0.0020 - 0.0098 inch)
Example:
When, L = 90.50 mm (3.5360 inch), l = 90.35 mm (3.5571 inch)
Calculation when clearance is 0.05 mm (0.0020 inch)
H = (90.50 + 0.45) - 90.35 - 0.05 = 0.55
[H = (3.5630 + 0.0177) - 3.5571 - 0.0020 = 0.0217]
Calculation when clearance is 0.25 mm (0.0098 inch)
H = (90.50 + 0.45) - 90.35 - 0.25 = 0.35
[H = (3.5630 + 0.0177) - 3.5571 - 0.0098 = 0.0138]





After calculation, the value of H becomes between 0.35 mm (0.0138 inch)-0.55 mm (0.0217 inch), therefore select either 2 shims of a thickness 0.2 mm (0.010 inch) each, or 1 shim 0.5 mm (0.020 inch) thick.