tf(2), Y61
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//-->TRANSFERSECTIONGIMATFEMLCECFECONTENTSPREPARATION................................................................2Special Service Tools ..................................................2Commercial Service Tools ...........................................3NOISE, VIBRATION AND HARSHNESS (NVH)TROUBLESHOOTING.....................................................4NVH Troubleshooting Chart.........................................4DESCRIPTION.................................................................5Cross-sectional View ...................................................5ON-VEHICLE SERVICE..................................................6Replacing Oil Seal .......................................................6Checking Position Switch ............................................8REMOVAL AND INSTALLATION....................................9Removal.......................................................................9Installation....................................................................9TRANSFER GEAR CONTROL.....................................10MAJOR OVERHAUL.....................................................11Case Components .....................................................11Gear Components .....................................................12Shift Control Components .........................................13DISASSEMBLY..............................................................14REPAIR FOR COMPONENT PARTS............................20Mainshaft ...................................................................20Front Drive Shaft .......................................................21Counter Gear .............................................................22Main Gear ..................................................................23Front Case .................................................................25Front Case Cover ......................................................25Center Case...............................................................26Bearing Retainer........................................................26Rear Case..................................................................26Shift Control Components .........................................27ASSEMBLY....................................................................29SERVICE DATA AND SPECIFICATIONS (SDS)..........35General Specifications...............................................35Inspection and Adjustment ........................................35CLMTATPDFARABRSTRSBTHAELSEIDXPREPARATIONSpecial Service Tools*: Special tool or commercial equivalentTool numberTool nameKV38104700*Flange wrenchDescriptionRemoving front companion flange nutInstalling front companion flange nutNT428ST30021000*PullerRemoving counter gear front bearingNT411ST30031000*PullerRemoving counter gear rear bearingNT411ST33290001*PullerRemoving center case oil sealRemoving rear oil sealNT414ST22452000*DriftInstalling mainshaft rear bearingNT065ST33061000*Drifta: 45 mm (1.77 in) dia.b: 36 mm (1.42 in) dia.Removing main gear bearingNT116ST30613000*Drifta: 28.5 mm (1.122 in) dia.b: 38 mm (1.50 in) dia.Installing counter gear rear bearingInstalling main gear bearingInstalling cover oil seala: 72 mm (2.83 in) dia.b: 48 mm (1.89 in) dia.Installing counter gear front bearingRemoving cover oil sealNT073ST33200000*DriftNT091ST30720000*Drifta: 60 mm (2.36 in) dia.b: 44.5 mm (1.752 in) dia.Installing counter case oil sealNT115a: 77 mm (3.03 in) dia.b: 55.5 mm (2.185 in) dia.TF-2PREPARATIONCommercial Service ToolsTool namePullerDescriptionRemovingRemovinggearRemovingRemovingRemovingRemovingfront and rear companion flangesmainshaft rear bearing and clutchL & H hubfront drive shaft front bearingfront drive shaft rear bearingmain gear bearingGIMAEMLCECNT077DriftInstalling shift shaft oil sealNT117a: 26 mm (1.02 in) dia.b: 20 mm (0.79 in) dia.c: 40 mm (1.57 in)Installing L & H hubFECLMTDriftNT117a: 60 mm (2.36 in) dia.b: 50 mm (1.97 in) dia.c: 60 mm (2.36 in)Installing clutch gearATDriftNT117a: 55 mm (2.17 in) dia.b: 45 mm (1.77 in) dia.c: 160 mm (6.30 in)Installing rear oil sealPDFARADriftNT117a: 75 mm (2.95 in) dia.b: 67 mm (2.64 in) dia.c: 60 mm (2.36 in)BRSTRSBTHAELSEIDXTF-3TRANSFERUse the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-tion. If necessary, repair or replace these parts.SymptomJumps out of gearHard to shift or will not shift1Fluid leakage3NoiseFLUID (Level low)12FLUID (Wrong)SUSPECTED PARTS(Possible cause)Refer to MA section (“Checking Transfer Fluid”,“CHASSIS AND BODY MAINTENANCE”).Reference pageNOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGNVH Troubleshooting ChartTF-4122FLUID (Level too high)12233122LIQUID GASKET (Damaged)TF-11OIL SEAL (Worn or damaged)TF-11CHECK SPRING AND CHECK BALL (Worn or damaged)TF-11, TF-13SHIFT FORK (Worn)TF-13GEAR (Worn or damaged)TF-12BEARING (Worn or damaged)TF-12BAULK RING (Worn or damaged)TF-12SHIFTING INSERT (Damaged)TF-12DESCRIPTIONCross-sectional ViewGIMAEMLCECFECLMTATPDFARABRSTRSBTHAELSEIDXSMT248DTF-5
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