Workshop Manual

4D2–28
TRANSFER CASE (TOD)
13.Install the snap ring of the input shaft bearing to the
transfer case.
265RY00003
14.Using snap ring pliers, open the snap ring from the
gap on the carrier assembly.
While opening the snap ring, securely attach the input
shaft and carrier assembly to the transfer case.
265RY00002
Inspection and Repair (Transfer Case
Assembly)
When wear, damage, or any other defects are observed
during the inspection, the part or parts must be repaired or
replaced. Wash all the parts with clean detergent, and
check that old oil, metallic particles, dirt, or foreign
materials are completely removed. Blow the air into oil
holes and grooves to remove foreign materials or residual
detergent.
Chain
B Check whether the face that contacts the sprocket is
free from excessive wear or damage. If defects are
observed, replace the part.
B If the chain interference mark is found on the inside
wall of the transfer cover or the chain is so slack that a
skipped engagement occurs between the chain and
sprocket, replace the chain.
Sprocket
B Check whether the sprocket tooth surface is
excessively worn or damaged, and there is evidence
of burrs, chipping, wear, or damage on the gear
spline. Remove minor flaws or scratches with oil
stone. If excessive wear or damage is observed,
replace the part.
B If excessive wear or damage is observed on the
sprocket inside sliding surface, replace the part.
Gear
B Check whether the gear tooth surface is excessively
worn or damaged, and there is evidence of burrs,
chipping, wear, or damage on the gear spline.
Remove minor flaws or scratches with oil stone. If
excessive wear or damage is observed, replace the
part.
Thickness of Reduction Hub
B Measure the thickness with a micrometer.
B If the measurement exceeds the limit, replace the
reduction hub.
Standard : 3.05–3.30 mm (0.120–0.130 in)
Allowable limit : 2.5 mm (0.098 in)
265RW005