SERVICE DATA
| Transfer unit | ||||
|---|---|---|---|---|
| Hose installation depth | 13 mm (0.51 in.) or more | |||
| Oil pump body | ||||
| Body clearance | STD | 0.09 to 0.16 mm (0.0035 to 0.0063 in.) | ||
| Max. | 0.16 mm (0.0063 in.) | |||
| Tip clearance | STD | 0.05 to 0.15 mm (0.0020 to 0.0059 in.) | ||
| Max. | 0.15 mm (0.0059 in.) | |||
| Side clearance | STD | 0.03 to 0.10 mm (0.0012 to 0.0039 in.) | ||
| Max. | 0.10 mm (0.0039 in.) | |||
| Rear output shaft | ||||
| Drive sprocket thrust clearance | STD | 0.10 to 0.25 mm (0.0039 to 0.0098 in.) | ||
| Max. | 0.25 mm (0.0098 in.) | |||
| Rear output shaft journal outer diameter | ||||
| (part A) | Min. | 27.98 mm (1.1016 in.) | ||
| (part B) | Min. | 36.98 mm (1.4561 in.) | ||
| Drive sprocket radial clearance | STD | 0.010 to 0.055 mm (0.0004 to 0.0022 in.) | ||
| Max. | 0.055 mm (0.0022 in.) | |||
| Front drive shift fork to clutch sleeve clearance | Max. | 1.0 mm (0.039 in.) | ||
| High and low shift fork to clutch sleeve clearance | Max. | 1.0 mm (0.039 in.) | ||
| Rear output shaft snap ring thickness | Mark | |||
| A | 2.10 to 2.15 mm (0.0827 to 0.0846 in.) | |||
| B | 2.15 to 2.20 mm (0.0846 to 0.0866 in.) | |||
| C | 2.20 to 2.25 mm (0.0866 to 0.0886 in.) | |||
| D | 2.25 to 2.30 mm (0.0886 to 0.0906 in.) | |||
| E | 2.30 to 2.35 mm (0.0906 to 0.0925 in.) | |||
| F | 2.35 to 2.40 mm (0.0925 to 0.0945 in.) | |||
| G | 2.40 to 2.45 mm (0.0945 to 0.0965 in.) | |||
| H | 2.45 to 2.50 mm (0.0965 to 0.0984 in.) | |||
| J | 2.50 to 2.55 mm (0.0984 to 0.1004 in.) | |||
| K | 2.00 to 2.05 mm (0.0787 to 0.0807 in.) | |||
| L | 2.05 to 2.10 mm (0.0807 to 0.0827 in.) | |||
| Input shaft | ||||
| Input shaft journal outer diameter | Min. | 47.59 mm (1.8736 in.) | ||
| Input shaft bushing diameter | Max. | 39.14 mm (1.5409 in.) | ||
| Synchronizer ring to sprocket clearance | STD | 1.05 to 1.85 mm (0.0413 to 0.0728 in.) | ||
| Min. | 0.80 mm (0.0315 in.) | |||
| Input shaft snap ring thickness | Mark | |||
| A | 2.10 to 2.15 mm (0.0827 to 0.0846 in.) | |||
| B | 2.15 to 2.20 mm (0.0846 to 0.0866 in.) | |||
| C | 2.20 to 2.25 mm (0.0866 to 0.0886 in.) | |||
| D | 2.25 to 2.30 mm (0.0886 to 0.0906 in.) | |||
| E | 2.30 to 2.35 mm (0.0906 to 0.0925 in.) | |||
| F | 2.35 to 2.40 mm (0.0925 to 0.0945 in.) | |||
| G | 2.40 to 2.45 mm (0.0945 to 0.0965 in.) | |||
| H | 2.45 to 2.50 mm (0.0965 to 0.0984 in.) | |||
| J | 2.50 to 2.55 mm (0.0984 to 0.1004 in.) | |||
| K | 2.55 to 2.60 mm (0.1004 to 0.1024 in.) | |||
| L | 2.60 to 2.65 mm (0.1024 to 0.1043 in.) | |||
| M | 2.65 to 2.70 mm (0.1043 to 0.1063 in.) | |||
| N | 2.70 to 2.75 mm (0.1063 to 0.1083 in.) | |||
| P | 2.75 to 2.80 mm (0.1083 to 0.1102 in.) | |||
| Q | 2.80 to 2.85 mm (0.1102 to 0.1122 in.) | |||
| R | 2.85 to 2.90 mm (0.1122 to 0.1142 in.) | |||
| S | 2.90 to 2.95 mm (0.1142 to 0.1161 in.) | |||
| T | 2.95 to 3.00 mm (0.1161 to 0.1181 in.) | |||
| U | 3.00 to 3.05 mm (0.1181 to 0.1201 in.) | |||
| Planetary gear | ||||
| Pinion gear thrust clearance | STD | 0.11 to 0.84 mm (0.0043 to 0.0331 in.) | ||
| Max. | 0.84 mm (0.0331 in.) | |||
| Pinion gear radial clearance | STD | 0.009 to 0.038 mm (0.0004 to 0.0015 in.) | ||
| Max. | 0.038 mm (0.0015 in.) | |||
| Outer bearing snap ring thickness | Mark | |||
| 1 | 1.45 to 1.50 mm (0.0571 to 0.0591 in.) | |||
| 2 | 1.50 to 1.55 mm (0.0591 to 0.0610 in.) | |||
| 3 | 1.55 to 1.60 mm (0.0610 to 0.0630 in.) | |||
| 4 | 1.60 to 1.65 mm (0.0630 to 0.0650 in.) | |||
| 5 | 1.65 to 1.70 mm (0.0650 to 0.0669 in.) | |||
| Inner bearing press in depth | 7.7 to 8.3 mm (0.303 to 0.327 in.) | |||
| Oil seal | ||||
| Shift fork shaft oil seal drive in depth | 0.5 to 0.5 mm (-0.020 to 0.020 in.) | |||
TRANSFER CASE SERVICE SPECIFICATIONS