Transfer Clutch: Assembly

1. Install the transfer clutch piston, return spring and transfer clutch piston seal.
   NOTE:

   • Apply CVTF to the seal section of transfer clutch piston. 
   • Apply CVTF to the lip section of transfer clutch piston seal. 

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2. Compress the return spring using the ST and a press to install the snap ring.

   Preparation tool: 

   ST: COMPRESSOR SPECIAL TOOL (18762AA001)

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3. Blow compressed air through the hole shown in the figure, and check the transfer clutch piston operation.

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4. Select the transfer clutch plate set and pressure plate (rear side).
   NOTE:

   The pressure plate (front side) is included in the transfer clutch plate set. 

   1. Set the pressure plate (rear side) and transfer clutch plate set to the rear drive shaft, and then install the snap ring.
      NOTE:

      Face the smooth side of the pressure plate (rear side) toward the transfer clutch plate set. 

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   2. Set the shim, etc. (A) between the snap ring and pressure plate (front side) so that each plate does not tilt.

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   3. Measure the clearance "C" between the snap ring and pressure plate (front side) using a thickness gauge.

      Service limit: 

      1.45 mm (0.057 in)

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   4. If the value exceeds the limit, perform the following procedures.
   1. Measure the thickness of the pressure plate (front side) and pressure plate (rear side).
   2. Replace with a new transfer clutch plate set that includes a pressure plate (front side) whose thickness is close to the measured thickness of pressure plate (front side), and perform measurement from step  2 again.

      Initial standard: 

      0.7 - 1.1 mm (0.03 - 0.04 in)

   3. If it exceeds the initial standard value, adjust the thickness of pressure plate (rear side) so that the value falls within the initial standard.
5. Press-fit a new ball bearing using ST1, ST2 and a press.

Preparation tool: 

ST1: INSTALLER (398177700)

ST2: EXTENSION DRIVE SHAFT (927130000)

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