Usage:
(1) Torque for drive flange bolt ... 100 ± 20 N·m (73.5294 ± 14.7058 lb ft)
(2) Drive flange seal installation depth (A) ... 6.0 mm (.250 in)
(3) Transfer drive group mounting gaskets:
7T-3174 Thickness ... 0.25 mm (.010 in)
7T-3175 Thickness ... 0.50 mm (.020 in)
Use one gasket as required to obtain backlash between the transmission countershaft gear and transfer drive gear (6) of ... 0.25 ± 0.05 mm (.010 ± .002 in)
(4) Thickness of one new 6Y-7929 Disc
Assembly ... 2.05 ± 0.08 mm (.081 ± .003 in)
Minimum allowable thickness of disc assembly ... 1.48 mm (.058 in)
(5) Thickness of one new 6T-9194 Plate ... 1.78 to 1.88 mm (.070 to .074 in)
(6) Transfer box drive gear.
(7) Transfer box drive shaft end play ... 0.025 to 0.076 mm (.001 to .003 in)
Drive shaft end play shims; use one as required to adjust drive shaft end play.
Shim thicknesses
0.51 mm (.002 in)
0.076 mm (.003 in)
0.127 mm (.005 in)
0.178 mm (.007 in)
0.381 mm (.015 in)
0.508 mm (.020 in)
(8) Torque for end cover bolts ... 45 to 64 N·m (33 to 47 lb ft)
(9) Torque for adapter bolts ... 45 to 64 N·m (33 to 47 lb ft)
NOTE: Use 5P-3413 Thread Sealant on adapter bolts.
(10) Drive shaft.
(11) Drive shaft front bearing.
(12) Torque for transfer box installation bolts ... 45 to 64 N·m (33 to 47 lb ft)
(13) Drive shaft rear bearing.
(14) Torque for drive shaft assembly nut ... 54 to 82 N·m (40 to 60 lb ft)
(15) Torque for solenoid ... 34 to 54 N·m (25 to 40 lb ft)
(16) 8E-9322 Spring for solenoid valve:
Length under test force ... 21.3 mm (.84 in)
Test Force ... 8 N (1.8 lb)
Free length after test ... 34 mm (1.34 in)
Outside diameter ... 10.3 mm (.41 in)
Adjustment Procedure
Transfer Box Drive Gear Mesh at Installation
NOTE: At the time of installation the proper transmission countershaft gear and transfer box drive gear mesh is important. This is accomplished by using a gasket of the proper thickness.
1. Install the transfer box using the 7T-3175 Gasket ... 0.50 mm (.020 in).
2. Tighten bolts to a torque of ... 45 to 64 N·m (33 to 47 lb ft).
3. Measure the gear backlash at the drive flange. If the backlash exceeds the specification of 0.25 ± 0.05 mm (.010 ± .002 in), remove the 7T-3175 Gasket and install the 7T-3174 Gasket ... 0.25 mm (.010 in).
Transfer Box Drive Shaft End play
1. With the transfer box assembled install the end cover without shims and tighten the bolts to a torque of ... 45 N·m (33 lb ft).
2. Measure transfer box drive shaft end play. Subtract 0.051 mm (.002 in) from the measured dimension. This is the required shim thickness.
3. Remove the end cover and install the proper shim. Tighten the cover bolts to a torque of ... 45 to 64 N·m (33 to 47 lb ft).
4. Measure the shaft end play once more. It must be ... 0.025 to 0.076 mm (.001 to .003 in).