Workshop Manual

4D2–15
TRANSFER CASE (TOD)
Reassembly
Transfer cover oil seal replacement
1.Remove the oil seal from the transfer cover assembly.
2.Apply oil to the circumference of the new oil seal and
fill the lip with grease (BESCO L2 or its equivalent).
3.Using the oil seal installer J–42804, install the oil seal
to the transfer cover assembly.
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Shift shaft oil seal replacement
4.Remove the oil seal from the transfer cover assembly.
5.Apply oil the circumference of the new oil seal.
6.Using the oil seal installer J–33951, install the oil seal
to the transfer cover assembly.
The drive in depth must be 9.4 ∼ 10.4 mm (0.370 ∼
0.409 in). The knurled end of the installer (indicated
by the arrow) must be flush with the oil seal
installation surface.
NOTE: Use care to prevent tilt to oil seal when installing
oil seal to the case.
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7.Install the ball bearing of the front output shaft to the
transfer cover.
8.Install the speed gear and tone wheel.
9.Install the ball bearing to the transfer cover.
10.Using snap ring pliers, install the snap ring to the
transfer cover.
NOTE: The snap ring must be fully inserted into the
transfer cover snap ring groove.
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11.Install the coil assembly to the transfer cover and
tighten the set nuts (3 pieces) to the specified torque.
Torque: 10 N·m (87 lb in)
12.Install the connector to the harness terminal of the coil
assembly.
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