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TRANSFER CLUTCH

Automatic Transmission

B : INSTALLATION 55,058

10. Transfer Clutch s5,o588

A: REMOVAL

1) Install the transfer clutch assembly to the case.

5510588A78

CAUTION :
Be careful not to damage the seal rings.

1) Remove rear vehicle speed sensor .
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B)

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-

O O

-

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(A)
)-B3M1056C

(A)
(B)

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Rear vehicle speed sensor
Front vehicle speed sensor

2) Separate

case

transmission

case sections .

O

and extension

(A)
(B)

O

O

~v
p
p

I
B3M1106B~'

Transfer clutch
Extension case

2) Tighten bolts to secure the case .
Tightening torque:
25 N~m (2.5 kgf-m, 18.1 ft-Ib)

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B3M1057

3) Take out the transfer clutch by lightly tapping
the end of the rear drive shaft.
CAUTION :
Be careful not to damage the oil seal in the
extension .

I

B3M,o5,l

C : DISASSEMBLY

1) Remove the seal ring .

CAUTION:
Be careful not to damage the seal ring .

(A)

B3M10898

(A)
(B)

S570588A06

Transfer clutch
Extension case
(B)

AT40

Transfer clutch

ST2 and ST3. and take out the return spring and transfer clutch piston seal . CAUTION : Do not reuse the bearing. drive plates. REMOVER G3M0497 D : ASSEMBLY 55. ST 498077600 Au tomatic Transmission 5) Apply compressed air to the rear drive shaft to remove the piston . remove the ball bearing . ST1 399893600 PLIERS ST2 398673600 COMPRESSOR ST3 398623600 SEAT 2) Install return spring to transfer piston . (A) (B) 1) Install the transfer clutch piston .TRANSFER CLUTCH 2) Using a press and ST. and take out the pressure plate. (A) (B) Snap ring Transfer clutch 4) Remove the snap ring with ST1. (A) (B) (A) (B) Snap ring Return spring AT41 Transfer clutch piston Transfer clutch Return spring Transfer clutch .°z 3) Remove the snap ring. and driven plates ..

6) Using ST1 and ST2. pressure plate and snap ring . ST1 ST2 499257300 SNAP RING OUTER GUIDE 499247400 INSTALLER I ST2 I ST1 (A) (B) Transfer clutch piston seal Transfer clutch (A) 4) Install ST to rear drive shaft. drive plates. ST 499257300 SNAP RING OUTER GUIDE ST (A) Snap ring 8) Apply compressed air to see if the assembled parts move smoothly. install snap ring to rear drive shaft.TRANSFER CLUTCH Auto mat ic Transmission 3) Install transfer clutch piston seal. -(A) B3M1402C (A) Transfer clutch 5) Install snap ring to ST. ST 499257300 SNAP RING OUTER GUIDE (B) 83M1181CI ST (A) (B) Snap ring Transfer clutch 7) Install the driven plates. NOTE : After installing snap ring. 83M 11 BOC (A) (B) Snap ring Transfer clutch AT42 . remove ST1 and ST2.

5 (0.> WITH VTD <Ref . ADJUSTMENT.7 . adjust it by selecting a suitable pressure plate on the transfer clutch piston side . Check the snap ring for wear.6 mm (0. Available pressure plates Part No . WITHOUT VTD <Ref.1. Transfer Clutch . return spring for permanent set and breakage.> AT43 . Automatic Transmission 11) Coat the seal ring with vaseline. * If the clearance is not within specification.TRANSFER CLUTCH 9) Check the clearance. place the same thickness of shim on both sides to prevent pressure plate from tilting . CAUTION: Do not expand the seal ring excessively when installing .146) 31593AA171 4.1 (0 .0.063 in) (A) (B) Seal rings Transfer clutch 12) Install the transfer clutch assembly to the case.1 mm (0. ADJUSTMENT.3 (0 .7 (0 . " Measure the extension end play and adjust it to within specifications .177) 10) Press-fit the ball bearing with ST. to AT-44 WITHOUT VTD.043 in) Allowable limit: 1. and install it in the seal ring groove of the shaft.028 .161) 31593AA181 I 4. ST 899580100 INSTALLER (A) (B) Transfer clutch Extension case E : INSPECTION (A) Ball bearing S570588A70 * Check the drive plate facing for wear and damage. Transfer Clutch . Thickness mm (in) 31593AA151 3. and return spring for deformation . Standard value: 0. to AT-44 WITH VTD. CAUTION : Be careful not to damage the seal rings. Check the lathe cut ring for damage .130) 31593AA161 3. NOTE : Before measuring clearance.

165) 4.05 .97 in) ST 398643600 GAUGE ST1 e l I B3M1114A 3) Calculation equation : NOTE: Add 0 . ST 398643600 GAUGE L = Measured value .2 (0 .4 (0 .8 (0 .25 mm (0.0 (0 .1 .0 .0. Calculate formula 2 to determine "H" . Select shims of suitable thicknesses within the calculated "H" range. ST 0 L B3M0985A 2) Measure the distance "E" from the transmission case mating surface to the reduction drive gear end surface with ST1 and ST2 .50 mm (~ = Measured value . The calculated "H" refers to the shim thickness range . f = Measured value . 806536020 806535030 806535040 806535050 806535060 806535070 806535090 5510588A0707 1) Measure distance L from end of extension case and rear drive shaft with ST. WITH VTD S510588A0102 1) Install the rear drive shaft into the reduction drive gear and center differential assembly.TRANSFER CLUTCH Automatic Transmission F : ADJUSTMENT 1 .0177 in)] 2: Height from end of transmission case to end of reduction drive gear H: Thrust needle bearing thickness 0 .8 (0 . WITHOUT VTD Thrust needle bearing Thickness mm (in) 3.50 mm (2 = Measured value .0098 in) thick shims to area "T".05 mm (0.157) 4.0.173) 4.0020 in) and 0 .59 in) 2.0 (0 .189) 5.197) 5510588A01 Part No. T=(L+G)-f -H T: Shim clearance L: Distance from end of extension case to end of rear drive shaft G: Gasket thickness [0.0098 in) AT44 .45 mm (0.25 mm (0.15 mm (L = Measured value .6 (0 .181) 4.150) 4.1 .0020 .97 in) ST1 398643600 GAUGE ST2 499577000 GAUGE ST2 (A) (B) Rear drive plate Center differential carrier 2) Measure the distance "C" from the transmission case mating surface to the reduction drive gear end surface with ST ~ = Measured value .

TRANSFER CLUTCH 3) Calculation equation : NOTE: Add 0 .20 mm (0 .0079 in) thick shims to area "T".0 . (0 to 4 teeth) T=(L+G)-f -H T: Shim clearance L: Distance from end of extension case to end of rear drive shaft G: Gasket thickness [0.05 mm (0.5 AT45 Automatic Transmission .05 .0020 .2 0 .25 mm (0 .0020 in) and 0 . The calculated "H" refers to the shim thickness range .0 .0177 in)] f : Height from end of transmission case to end of reduction drive gear H : Shim thickness 0.0098 in) Part No . 3281 AA001 3281 AA011 Adjusting shim ~ Thickness 0. Calculate formula 2 to determine "H" . Select shims of suitable thicknesses within the calculated "H" range .45 mm (0 .