Transfer Case: Other Nissan Juke I facelift

Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"

The Supplemental Restraint System such as "AIR BAG" and "SEAT BELT PRE-TENSIONER", used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front air bag, depending on the severity of a collision and whether the front occupants are buckled or unbuckled.

Information necessary to service the system safely is included in the SRS AIRBAG and SEAT BELTS of this Service Information.

PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS

Scheme 61

1. When removing the 12V battery terminal, turn OFF the ignition switch and wait at least 30 seconds. NOTE: ECU may be active for several tens of seconds after the ignition switch is turned OFF. If the battery terminal is removed before ECU stops, then a DTC detection error or ECU data corruption may occur.
2. For vehicles with the 2-batteries, be sure to connect the main battery and the sub battery before turning ON the ignition switch. NOTE: If the ignition switch is turned ON with any one of the terminals of main battery and sub battery disconnected, then DTC may be detected.
3. After installing the 12V battery, always check "Self Diagnosis Result" of all ECUs and erase DTC.

Note. The removal of 12V battery may cause a DTC detection error.

Service Notice or Precautions for Transfer

1. After overhaul refill the transfer with new transfer oil.
2. Check the oil level or replace the oil only with the vehicle parked on level surface.
3. During removal or installation, keep inside of transfer clear of dust or dirt.
4. Replace all tires at the same time. Always use tires of the proper size and the same brand and pattern. Fitting improper size and unusual wear tires applies excessive force to vehicle mechanism and can cause longitudinal vibration.
5. Disassembly should be done in a clean work area.
6. Before proceeding with disassembly, thoroughly clean the transfer. It is important to prevent the internal parts from becoming contaminated by dirt or other foreign matter.
7. Check for the correct installation status prior to removal or disassembly. If matching marks are required, be certain they do not interfere with the function of the parts when applied.
8. All parts should be carefully cleaned with a general purpose, non-flammable solvent before inspection or reassembly.
9. Check appearance of the disassembled parts for damage, deformation, and unusual wear. Replace them with a new one if necessary.
10. Gaskets, seals and lock nuts should be replaced any time when the transfer is disassembled.
11. When replacing the parts, use the genuine parts.
12. In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If tightening sequence is specified, use it.
13. Observe the specified torque when assembling.
14. Clean and flush the parts sufficiently and blow-dry them.
15. Never damage sliding surfaces and mating surfaces.
16. Use lint-free cloth or towels for wiping parts clean. Common shop rags can leave fibers that could interfere with the operation of the transfer.
17. When loosening pinion lock nut, replace collapsible spacer.
18. Dispose of the waste oil using the methods prescribed law, ordinance, etc., after replacing transfer oil.
19. After removing transfer assembly from the vehicle, when replace transfer case oil seals (right and left). NOTE: Transfer case oil seals (right and left) cannot be replaced on vehicle, because there is not enough room.

Special Service Tools

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.

Tool number (Kent-Moore No.) Tool name Description ST33200000 (J-26082) Drift 60 mm (2.36 in) dia. 44.5 mm (1.752 in) dia. Removing inner race of ring gear bearing (right). KV381054S0 (J-34286) Puller Removing drive shaft oil seal. Removing drive pinion oil seal. ST33230000 (J-25805-01) Drift 51 mm (2.01 in) dia. 41 mm (1.61 in) dia. 28.5 mm (1.122 in) dia. Installing drive shaft oil seal. Installing outer race of pinion bearing (rear). ST3127S000 (J-25765-A) Preload gauge Measuring pinion bearing preload and total preload. ST35272000 (J-26092) Drift 80 mm (3.15 in) dia. 38 mm (1.50 in) dia. 31 mm (1.22 in) dia. Installing inner race of pinion bearing (front). ST37830000 (-) Drift 39 mm (1.54 in) dia. 62 mm (2.44 in) dia. Installing outer race of pinion bearing (front). ST27863000 (-) Drift 62 mm (2.44 in) dia. 52 mm (2.05 in) dia. Installing transfer case oil seal (left). ST35271000 (J-26091) Drift 72 mm (2.83 in) dia. 63 mm (2.48 in) dia. Installing transfer case oil seal (right)

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Commercial Service Tools

Tool name Description Replacer Remove inner race of ring gear bearing (left). Remove inner race of ring gear bearing (right). Remove inner race of pinion bearing (front). Drift 54 - 55 mm (2.13 - 2.17 in) dia. 51 - 52 mm (2.01 - 2.05 in) dia. 85 mm (3.35 in) or more Install inner race of ring gear bearing (left). Drift 64 - 66 mm (2.52 - 2.60 in) dia. 60 - 62 mm (2.36 - 2.44 in) dia. 50 mm (1.97 in) or more Install inner race of ring gear bearing (right). Drift 60 - 61 mm (2.36 - 2.40 in) dia. 57 - 58 mm (2.24 - 2.28 in) dia. 85 mm (3.35 in) or more Compressing ring gear assembly with ring gear bearing. Drift 73 - 74 mm (2.87 - 2.91 in) dia. 70 - 71 mm (2.76 - 2.80 in) dia. 30 mm (1.18 in) or more Compressing ring gear assembly with ring gear bearing. Puller Remove companion flange. Drift 53 - 56 mm (2.09 - 2.13 in) dia. 48 - 51 mm (1.81 - 2.01 in) dia. Installing drive pinion oil seal. Drift 55 mm (2.17 in) dia. or more Installing transfer case oil seal (left)

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AWD Control Module

1. AWD control module controls driving force distribution by signals from each sensor from front wheel driving mode (100:0) to 4-wheel driving mode (50:50).
2. Driving torque between both rear wheels is automatically controlled between 100:0 and 0:100 during acceleration and cornering.
3. Make the vehicle fail-safe condition if malfunction is detected in AWD system. For fail-safe function, refer to " «FAIL-SAFE»(ref-621388-S11380194682014061000000) ".
4. AWD actuator relay is integrated with AWD control module, and supplies AWD solenoid with voltage.
5. Self-diagnosis can be done with CONSULT.

AWD Solenoid

AWD solenoid is integrated with each electric controlled coupling, and controls electric controlled couplings by command current from AWD control module.

Electric Controlled Coupling

Electric controlled couplings are integrated with rear final drive and transmits driving force to rear drive shaft.

For operation, refer to " OPERATION PRINCIPLE ".

AWD Mode Switch

1. AWD mode is selectable among 2WD, AWD-V, and AWD by operating the AWD mode switch while the ignition switch is ON or the engine is running.
2. Tilting the switch to the 2WD/AWD side allows mode selection between 2WD and AWD. To switch mode to AWD-V, simply position the switch in AWD-V (neutral position).

AWD Warning Lamp

1. After the AWD system is activated, the AWD warning lamp turns OFF during front and rear wheels driving torque distribution.
2. After the AWD system is deactivated by fail-safe function and torque distribution of front and rear wheels is stopped, the AWD warning lamp turns ON to indicate that the state is in 2WD. NOTE: The AWD warning lamp does not turn ON when only torque distribution of both rear wheels is stopped by the fail-safe function.
3. The AWD warning lamp blinks to indicate that the state is in 2WD when the AWD system is temporarily stopped by the protection function.
4. Also turns ON when ignition switch is turned ON, for the purpose of lamp check. Turns OFF after the engine starts if system is normal.

Note. AWD warning lamp also turns ON due to data reception error, CAN communication error etc.

AWD Mode Indicator Lamp

The following is the indications of AWD mode indicator lamp.

Scheme 68

1. Torque distribution indicator is displayed when the ODO/TRIP indication on the combination meter is switched.
2. The number of bars shows driving force distributed to each tire. (Maximum bars: 3)

Note. The driving force distribution may not match actual one. This is not a system malfunction.

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1. The AWD control module supplies command current to each electric controlled coupling (AWD solenoid).
2. Each of control clutch is engaged by electromagnet and torque is detected in control clutch.
3. The cam operates in response to control clutch torque and applies pressure to main clutch.
4. Each of main clutch transmits torque to right and left rear wheels according to pressing power. NOTE: Change each pressing power according to AWD mode status and cornering conditions. Transmission torque to the right and left rear wheels is determined according to command current.

Scheme 73

INPUT/OUTPUT SIGNAL

It transmits/receives each signal from the following AWD control module via CAN communication line.

2WD mode

1. Vehicle is in front-wheel drive.

AWD-V mode

Normal Control

Scheme 74

1. Pressing force of multiple disc clutch is controlled by electric control. Driving torque distribution of front and rear wheels changes automatically between approximately 100: 0 (Front wheel drive) and 50: 50 (AWD) to have an optimized torque distribution adapted to road condition change.
2. When slip occurs on front wheel, distribute optimum torque to rear wheel and keep stable driving.
3. On roads which do not require AWD, it contributes to improved fuel economy by driving in conditions close to front-wheel drive and it results in better fuel efficiency.

Cornering Control

Scheme 75

1. Torque between both rear wheels is automatically changed between 100: 0 and 0: 100 for distributing optimum torque that depends on the driving conditions and road surface conditions.
2. Producing a difference between both rear wheels enables sporty and smooth handling.
3. The vehicle cornering status is judged according to information from each sensor, and the optimum torque is distributed to rear wheels for preventing tight cornering/braking symptom.

AWD mode

1. The AWD mode controls torque for obtaining suitable torque for driving on slippery roads (e.g. snow-covered roads) and provides more stable driving, compared to AWD-V.

AWD SYSTEM: Fail-safe

When a system malfunction occurs, the AWD warning lamp turns ON and the AWD control becomes 2WD state.

AWD SYSTEM: Protection Function

AWD system activates its protection function (shuts down AWD system temporarily) if AWD system detects high load continuously, the front wheel tire size differs from the rear tire size or the rear right wheel tire size differs from the rear left tire size. (AWD system is automatically restored if AWD system no longer detects any overload or the tire size difference is eliminated.)

Note. If the warning lamp blinks slowly during driving but remains OFF after the engine is restarted, the system is normal. If it again blinks slowly after driving for some time, vehicle must be inspected. When there is a difference of revolution speed between the front and rear wheel the shift occasionally changes to direct 4-wheel driving conditions automatically. This is not a malfunction.

FREEZE FRAME DATA (FFD)

The following vehicle status is recorded when DTC is detected and is displayed.

DATA MONITOR

Note. The following table includes information (items) inapplicable to this vehicle. For information (items) applicable to this vehicle, refer to CONSULT display items.

WORK SUPPORT

PHYSICAL VALUES

Fail-safe

When a system malfunction occurs, the AWD warning lamp turns ON and the AWD control becomes 2WD state.

Protection Function

AWD system activates its protection function (shuts down AWD system temporarily) if AWD system detects high load continuously, the front wheel tire size differs from the rear tire size or the rear right wheel tire size differs from the rear left tire size. (AWD system is automatically restored if AWD system no longer detects any overload or the tire size difference is eliminated.)

Note. If the warning lamp blinks slowly during driving but remains OFF after the engine is restarted, the system is normal. If it again blinks slowly after driving for some time, vehicle must be inspected. When there is a difference of revolution speed between the front and rear wheel the shift occasionally changes to direct 4-wheel driving conditions automatically. This is not a malfunction.

DETAILED FLOW

1. INTERVIEW FROM THE CUSTOMER Clarify customer complaints before inspection. First of all, perform an interview utilizing " «DIAGNOSTIC WORK SHEET»(ref-621388-S20556770592014061000000) " and reproduce symptoms as well as fully understand it. Ask customer about his/her complaints carefully. Check symptoms by driving vehicle with customer, if necessary. CAUTION: Customers are not professional. Never guess easily like "maybe the customer means that...," or "maybe the customer mentions this symptom". : GO TO 2.
2. CHECK SYMPTOM Reproduce the symptom that is indicated by the customer, based on the information from the customer obtained by interview. Also check that the symptom is not caused by protection function. Refer to " «PROTECTION FUNCTION»(ref-621388-S16847170182014061000000) ". CAUTION: When the symptom is caused by normal operation, fully inspect each portion and obtain the understanding of customer that the symptom is not caused by a malfunction. : GO TO 3.
3. PERFORM SELF-DIAGNOSIS With CONSULT Perform self-diagnosis for "ALL MODE AWD/4WD". Is any DTC detected? YES: Record or print self-diagnosis results. GO TO 4. NO: GO TO 6 .
4. RECHECK SYMPTOM With CONSULT Erase self-diagnostic results for "ALL MODE AWD/4WD". Perform DTC confirmation procedures for the error detected system. NOTE: If some DTCs are detected at the same time, determine the order for performing the diagnosis based on " «DTC INSPECTION PRIORITY CHART»(ref-621388-S28543136402014061000000) ". Is any DTC detected? YES: GO TO 5. NO: Check harness and connectors based on the information obtained by interview. Refer to " «INTERMITTENT INCIDENT»(ref-621370-S29645329712014061000000) ".
5. REPAIR OR REPLACE ERROR-DETECTED PARTS Repair or replace error-detected parts. Reconnect part or connector after repairing or replacing. When DTC is detected, erase self-diagnostic results for "ALL MODE AWD/4WD". : GO TO 7 .
6. IDENTIFY ERROR-DETECTED SYSTEM BY SYMPTOM DIAGNOSIS Estimate error-detected system based on symptom diagnosis and perform inspection. Can the error-detected system be identified? YES: GO TO 7. NO: Check harness and connectors based on the information obtained by interview. Refer to " «INTERMITTENT INCIDENT»(ref-621370-S29645329712014061000000) ".
7. FINAL CHECK With CONSULT Check the reference value for AWD control module. Recheck the symptom and check that symptom is not reproduced on the same conditions. Is the symptom reproduced? YES: GO TO 3 . NO: INSPECTION END

Work Procedure

1. PERFORM WRITING UNIT CHARACTERISTICS Perform writing unit characteristics of electric controlled coupling. : Refer to " «WORK PROCEDURE»(ref-621388-S37760341342014061000000) ".

Component Function Check

1. CHECK AWD WARNING LAMP FUNCTION Check that AWD warning lamp turns ON when turn the ignition switch ON. Then, AWD warning lamp turns OFF approx. 1 second after the engine start. Is the inspection result normal? YES: INSPECTION END NO: Proceed to " «DIAGNOSIS PROCEDURE»(ref-621388-S10252387672014061000000) ".

1. AWD MODE INDICATOR LAMP OPERATION CHECK Turn the ignition switch ON. Set AWD mode switch to "AWD-V". Check that AWD mode indicator lamp (AWD-V) turns on. Is the inspection result normal? YES: INSPECTION END NO: Proceed to " «DIAGNOSIS PROCEDURE»(ref-621388-S12458167722014061000000) ".

1. AWD MODE INDICATOR LAMP OPERATION CHECK Check that AWD mode indicator lamp (AWD) turns on for approximately 1 second after the ignition switch is turned ON. Is the inspection result normal? YES: INSPECTION END NO: Proceed to " «DIAGNOSIS PROCEDURE»(ref-621388-S22305441692014061000000) ".

OIL LEAKAGE

Check transfer surrounding area (oil seal, drain plug, filler plug, and transfer case etc.) for oil leakage.

Scheme 76

1. Remove filler plug (1) and gasket. Then check that oil is filled up from mounting hole for the filler plug. CAUTION: Never start engine while checking oil level.
2. Before installing filler plug, set a new gasket. Install filler plug on transfer and tighten to the specified torque. Refer to " «EXPLODED VIEW»(ref-621388-S33496118632014061000000) ". CAUTION: Never reuse gasket.

Scheme 77

1. Run the vehicle to warm up the transfer unit sufficiently.
2. Stop the engine and remove the drain plug (1) and gasket to drain the transfer oil.
3. Before installing drain plug, set a new gasket. Install drain plug on the transfer and tighten to the specified torque. Refer to " «EXPLODED VIEW»(ref-621388-S33496118632014061000000) ". CAUTION: Never reuse gasket.

Scheme 78

1. Remove filler plug (1) and gasket. Then fill oil up to mounting hole for the filler plug. Oil and viscosity: Refer to " «RECOMMENDED FLUIDS AND LUBRICANTS»(ref-621382-S11847462522014061000000) ". Oil capacity: Refer to " «GENERAL SPECIFICATIONS»(ref-621388-S08894148832014061000000) ". CAUTION: Carefully fill the oil. (Fill up for approximately 3 minutes.)
2. Leave the vehicle for 3 minutes, and check the oil level again.
3. Before installing filler plug, set a new gasket. Install filler plug on transfer and tighten to the specified torque. Refer to " «EXPLODED VIEW»(ref-621388-S33496118632014061000000) ". CAUTION: Never reuse gasket.

Scheme 79

Gear and Shaft

Check gear face and shaft for wear, cracks, damage, and seizure.

Bearing

Check for seizure, peeling, wear, corrosion, sticking, unusual noise, roughness in hand turning, and other damage.

Shim

Check for seizure, damage, and unusual wear.

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1. Remove transfer cover. Refer to " «DISASSEMBLY»(ref-621388-S26892969592014061000000) ".
2. Remove ring gear shaft assembly. Refer to " «DISASSEMBLY»(ref-621388-S42012053822014061000000) ".
3. Remove pinion lock nut from the drive pinion.
4. Put matching marks (A) on screw ends of drive pinion and companion flange. CAUTION: Use paint to avoid scratching the surface.
5. Remove companion flange from drive pinion with the puller (A) (Commercial service tool).
6. Remove drive pinion oil seal from the transfer case with the puller (A) [SST: KV381054S0 (J-34286)]. CAUTION: Never damage transfer case.
7. Remove drive pinion assembly (1) from transfer case while tapping the drive pinion lightly with a plastic hammer. CAUTION: Never drop the drive pinion assembly.
8. Remove collapsible spacer from the drive pinion.
9. Remove inner race of pinion bearing (rear) from transfer case.
10. Remove inner race of pinion bearing (front) from drive pinion with the replacer (A) (Commercial service tool).
11. Tap the outer race of pinion bearing (rear) from transfer case with a brass rod to remove outer race of pinion bearing (rear). CAUTION: Never damage transfer case.
12. Remove drive pinion adjusting shim.
13. Perform inspection after disassembly. Refer to " «INSPECTION»(ref-621388-S09919358812014061000000) ".

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1. Select drive pinion adjusting shim. Refer to " «ADJUSTMENT»(ref-621388-S24830626542014061000000) ".
2. Install selected drive pinion adjusting shim to transfer case.
3. Install outer race of pinion bearing (rear) to the transfer case with the drift (A) [SST: ST37830000 (-)]. CAUTION: Never reuse pinion bearing. Apply gear oil to the pinion bearing.
4. Install inner race of pinion bearing (front) to drive pinion with the drift (A) [SST: ST35272000 (J-26092)]. CAUTION: Never reuse pinion bearing. Apply gear oil to the pinion bearing.
5. Assemble inner race of pinion bearing (rear) into the transfer case. CAUTION: Never reuse pinion bearing. Apply gear oil to the pinion bearing.
6. Using the drifts (A) (Commercial service tool), install drive pinion oil seal (1) to transfer case within the dimension (L) shown as follows. L: 0 - 0.6 mm (0 - 0.024 in) CAUTION: Never reuse oil seal. When installing, never incline oil seal. Apply multi-purpose grease onto oil seal lips, and gear oil onto the circumference.
7. Assemble a collapsible spacer onto the drive pinion. CAUTION: Never reuse the collapsible spacer.
8. Assemble drive pinion assembly into the transfer case, and then install companion flange to drive pinion. NOTE: Align matching marks (A) on the thread edge of drive pinion and companion flange, and install companion flange if drive pinion is reused.
9. Tap the companion flange (1) with a plastic hammer as far as the pinion lock nut can be tightened. CAUTION: Never damage drive pinion oil seal.
10. Apply anti-corrosive oil to the thread and seat of the pinion lock nut, and temporarily tighten pinion lock nut to the drive pinion. CAUTION: Never reuse pinion lock nut.
11. Tighten pinion lock nut within the specified torque range with the preload gauge (A) [SST: ST3127S000 (J-25765-A)] so that the drive pinion bearing preload is within standard. Drive pinion bearing preload: Refer to " «PRELOAD TORQUE»(ref-621388-S10589384742014061000000) ". CAUTION: Start the tightening of pinion lock nut from lower limit of the specified torque. Check the preload every 5° to 10° while tightening the pinion lock nut. Replace the collapsible spacer and tighten it again to adjust if preload exceeds the specified value. Never loosen pinion lock nut to adjust preload. After adjustment, rotate the drive pinion back and forth from 2 to 3 times to check for unusual noise, sticking, binding, and so on.
12. Install ring gear shaft assembly. Refer to " «ASSEMBLY»(ref-621388-S08842760572014061000000) ".
13. Install transfer cover to check and adjust each part. Refer to " «ASSEMBLY»(ref-621388-S17475772332014061000000) ". CAUTION: Never apply liquid gasket.
14. Check backlash, tooth contact, total preload and companion flange runout. Refer to " «ADJUSTMENT»(ref-621388-S24830626542014061000000) ". CAUTION: Measure the total preload without the transfer case oil seal.
15. Reinstall transfer cover for applying liquid gasket. Refer to " «ASSEMBLY»(ref-621388-S17475772332014061000000) ".
16. Install the transfer case oil seal (left and right). Refer to " «ASSEMBLY»(ref-621388-S17475772332014061000000) ".

Check gear face and shaft for wear, cracks, damage, and seizure.

Check for seizure, peeling, wear, corrosion, sticking, unusual noise, roughness in hand turning, and other damage.

Check for seizure, damage, and unusual wear.

Scheme 93

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Scheme 95

1. Remove transfer cover mounting bolts.
2. Lightly tap position (A) of transfer cover with a plastic hammer to remove transfer cover. CAUTION: When tapping of transfer cover, be sure to tap the back of cover.
3. Remove transfer case oil seal (right and left).
4. Remove ring gear shaft assembly. Refer to " «DISASSEMBLY»(ref-621388-S42012053822014061000000) ". NOTE: When the ring gear shaft removed, the following parts are simultaneously removed: Spacer (right and left) Ring gear bearing adjusting shim (right and left) Outer race of ring gear bearing (right and left)
5. Remove drive pinion assembly from transfer case. Refer to " «DISASSEMBLY»(ref-621388-S27487966772014061000000) ".
6. Tap the outer races of pinion bearing (front and rear) from transfer case with a brass rod to remove outer races of pinion bearing (front and rear). CAUTION: Never damage transfer case.
7. Remove drive pinion adjusting shim.
8. Remove dowel pin. CAUTION: Never remove dowel pin, if it is not necessary to replace.
9. Remove the filler plug and drain plug from the transfer case, and then remove each gasket.
10. Remove oil defense from transfer cover.
11. Perform inspection after disassembly. Refer to " «INSPECTION»(ref-621388-S11540521252014061000000) ".

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1. Install the oil defense to transfer cover.
2. Install gaskets onto filler plug and drain plug and install them into transfer case. CAUTION: Never reuse gasket. Install filler plug after oil is filled.
3. Install the dowel pin to transfer case. CAUTION: Never reuse the dowel pin.
4. Select drive pinion adjusting shim, and install it to transfer case. Refer to " «ADJUSTMENT»(ref-621388-S24830626542014061000000) ".
5. Install outer race of pinion bearing (front) to the transfer case with the drift (A) [SST: ST37830000 (-)]. CAUTION: Never reuse pinion bearing. Apply gear oil to the pinion bearing.
6. Install outer race of pinion bearing (rear) to transfer case with the drift (A) [SST: ST33230000 (J-25805-01)]. CAUTION: Never reuse pinion bearing. Apply gear oil to the pinion bearing.
7. Install drive pinion assembly to transfer case. Refer to " «ASSEMBLY»(ref-621388-S18571208272014061000000) ".
8. Install ring gear shaft assembly to transfer case. Refer to " «ASSEMBLY»(ref-621388-S08842760572014061000000) ".
9. Set the drifts (A and B) to right and left side spacers individually. Compress ring gear shaft assembly with ring gear bearing to install transfer cover to transfer case. CAUTION: Never apply gasket fluid on the mounting surface. Clean the mounting surface of transfer case and transfer cover to degrease sufficiently. The drift shall be placed on the center of the spacers. The pressure shall be as low as to install ring gear shaft assembly into transfer case. The maximum pressure shall be 10 kN (1 ton, 1.0 Imp ton). If the adjusting shims and spacers are installed by tapping, the transfer cover may be damaged. Avoid tapping.
10. Check backlash, tooth contact, and total preload. Refer to " «ADJUSTMENT»(ref-621388-S24830626542014061000000) ". CAUTION: Measure the total preload without the transfer case oil seals.
11. Remove transfer cover. Refer to " «DISASSEMBLY»(ref-621388-S26892969592014061000000) ".
12. Apply liquid gasket (1) to mating surface of transfer cover. Use Genuine Silicone RTV or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-621370-S30966015972014061000000) ". CAUTION: Remove old gasket on mounting surfaces. Also remove any moisture, oil, or foreign material on mounting surfaces. The width of sealant bend is 2 - 3 mm (0.08 - 0.012 in). Overlap both ends of the bead for at least 3 mm (0.012 in). Immediately install transfer cover after installing applying gasket.
13. Set the drifts (A and B) to right and left side spacers individually. Compress ring gear shaft assembly with ring gear bearing to install transfer cover to transfer case. CAUTION: Immediately install after applying gasket. The drift shall be placed on the center of the spacers. The pressure shall be as low as to install ring gear shaft assembly into transfer case. The maximum pressure shall be 10 kN (1 ton, 1.0 Imp ton). If the adjusting shims and spacers are installed by tapping, the transfer cover may be damaged. Avoid tapping.
14. Tighten transfer cover mounting bolts to the specified torque.
15. Using the drifts (A and B), install transfer case oil seal (left) (1) within the dimension (L) shown as follows. L: 1.0 - 1.6 mm (0.040 - 0.063 in) CAUTION: Never reuse oil seals. When installing, never incline oil seals. Apply multi-purpose grease onto oil seal lips, and gear oil onto the circumference of oil seal. Immediately install after installing transfer cover. After installing oil seal, immediately wipe out gasket squeezed out inward of transfer case.
16. Using the drifts (A) [SST: ST35271000 (J-26091)], install transfer case oil seal (right) (1) within the dimension (L) shown as follows. L: 0 - 0.6 mm (0 - 0.024 in) CAUTION: Never reuse oil seals. When installing, never incline oil seals. Apply multi-purpose grease onto oil seal lips, and gear oil onto the circumference of oil seal. Immediately install after installing transfer cover. After installing oil seal, immediately wipe out gasket squeezed out inward of transfer case.

Case and Cover

Check the cracks, damages, and bearing mounting surface for wear.

Backlash

Companion Flange Runout