Transfer Clutch: Assembly

Install the transfer clutch piston.

Fig 1: Installing Transfer Clutch Piston
Install return spring to transfer piston.

Fig 2: Installing Return Spring To Transfer Piston
Install transfer clutch piston seal.

Fig 3: Installing Transfer Clutch Piston Seal
Install ST to rear drive shaft.
ST 499257300 SNAP RING OUTER GUIDE

Fig 4: Installing ST To Rear Drive Shaft
Install snap ring to ST.
ST 499257300 SNAP RING OUTER GUIDE

Fig 5: Installing Snap Ring To ST
Using ST1 and ST2, install snap ring to rear drive shaft.
NOTE: After installing snap ring, remove ST1 and ST2.

ST1 499257300 SNAP RING OUTER GUIDE

ST2 499247400 INSTALLER

Fig 6: Installing Snap Ring To Rear Drive Shaft
Install the driven plates, drive plates, pressure plate and snap ring.

Fig 7: Installing Plates & Snap Ring
Apply compressed air to see if the assembled parts move smoothly.

Fig 8: Checking Clutch Pack For Smooth Movement
Check the clearance.
NOTE:
- Before measuring clearance, place the same thickness of shim on both sides to prevent pressure plate from tilting.
- If the clearance is not within specification, adjust it by selecting a suitable pressure plate on the transfer clutch piston side.
Standard value:
1. 0.7 - 1.1 mm (0.028 - 0.043 in)
Allowable limit:
1. 1.6 mm (0.063 in)
Fig 9: Measuring Clutch Pack Clearance

Fig 10: Pressure Plate Thickness Chart
Press-fit the ball bearing with ST.
ST 899580100 INSTALLER

Fig 11: Installing Ball Bearing
Coat the seal ring with vaseline, and install it in the seal ring groove of the shaft.
CAUTION: Do not expand the seal ring excessively when installing.

Fig 12: Installing Seal Ring
Install the transfer clutch assembly to the case.
CAUTION: Be careful not to damage the seal rings.

Fig 13: Installing Transfer Clutch Assembly