Table of contents: Adjusting washer of the ring gear…↓ Adjusting washer of the ring gear…↓ Pinion clutch adjusting shim ↓
Adjusting washer of the ring gear bearing on the transfer case side
1. Measure the dimensions F, H, I, R, U as shown in the figure.
2. Adjust the dimensions F, H, I, R, U to the values shown below.
- F: 163.00 mm (with an accuracy of 0.01 mm)
- H: 83.00 mm (with an accuracy of 0.01 mm)
- I: 131.90 mm (with an accuracy of 0.01 mm)
- R: 17.00 mm (with an accuracy of 0.01 mm)
- U: 89.50 mm (with an accuracy of 0.01 mm)
3. Check the Z dimension which is marked on the side of the drive gear.
Note: The Z dimension is the difference between the optimum and standard engagement with an accuracy of 0.01 mm.
4. Calculate the required thickness of the adjusting washer T1 of the ring gear bearing on the transfer case side using the formula below.
- T ₁ =(l-F+H+ZUR) x 0.01 + 1.49
5. Select the adjusting washer.
Attention:
Only one adjusting washer may be selected.
If there is no shim of the correct thickness, install a thicker shim that comes closest to the calculated thickness.
Adjusting washer of the ring gear bearing on the adapter housing side
1. Measure the dimensions F, H, J, K, U, and V as shown in the figure.
2. Adjust the dimensions F, H, J, K, U, and V to the values shown below.
- F: 163.00 mm (with an accuracy of 0.01 mm)
- H: 83.00 mm (with an accuracy of 0.01 mm)
- J: 109.50 mm (with an accuracy of 0.01 mm)
- K: 14.40 mm (with an accuracy of 0.01 mm)
- U: 89.50 mm (with an accuracy of 0.01 mm)
- V: 17.00 mm (with an accuracy of 0.01 mm)
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3. Check the Z dimension which is marked on the side of the drive gear.
Note: The Z dimension is the difference between the optimum and standard engagement with an accuracy of 0.01 mm.
4. Calculate the required thickness of the adjusting washer T2 of the ring gear bearing on the adapter housing side using the formula below.
- T ₂ =(K+FH-Z+UJV) x 0.01 +1.49
5. Select the adjusting washer.
Attention:
Only one adjusting washer may be selected.
If there is no shim of the correct thickness, install a thicker shim that comes closest to the calculated thickness.
Pinion clutch adjusting shim
1. Measure the distances L, N and Q as shown in the figure.
2. Check the dimension S, which is located on the end of the drive gear.
Note: Dimension S is the difference between the optimum and standard engagement with an accuracy of 0.01 mm.
3. Calculate the required thickness of the TZ adjusting shim using the formula below.
- T₃=(74,6+S)+N+Q-L
4. Select the thickness of the adjusting shim.
Only one adjustment shim may be selected.
