Disassembly

1.	Remove the O-ring(A) from the pinion shaft and case assembly.

2.	Remove the spacer(A).

3.	Loosen the HEX lock nut(A).

4.	Remove the rear flange assembly(A).

5.	Using the SST(09455-32200), remove the oil seal(A) from the pinion case.

6.	Using a press machine, remove the pinion shaft(A) from the pinion case(B).

7.	Take out the taper roller bearing(A) from the pinion case(B).

8.	Using a sliding hammer(A), remove the taper roller bearing outer race(B) from the pinion case(C).

Reassembly

1.	Assemble the taper roller bearing outer races.

2.	Using a press machine, install the taper roller bearing(C) and the pinion shaft(A) in the pinion case(B).

3.

Install the oil seal and the rear flange assembly as shown below and screw down the hex lock nut(A) until an axial clearance B of 0.25mm to 0.75mm between pinion and pinion case results. (1) Measurement of B A. Apply an additional 200N tension load F1 to the pinion head according to arrangement Y. Rotate the pinion 10 times and measure dimension C. B. Apply a 200N load F2 to the rear flange. Rotate the pinion 10 times and measure dimension D. B=C-D (2) Measure dimension Ev. (3) Tighten HEX lock nut. (4) Measure the drag torque of the pinion assembly. Target is 180-210Ncm. To achieve the target preload torque, it is permissible to gradually increase the tightening torque. If the permissible preload torque of 210Ncm is exceeded, it is not allowed to loosen Hex lock nut. Disassemble the whole pinion assembly. Replace the collapsible spacer and repeat the mounting procedure. (5) Measure dimension En. (6) Check preload. A preload torque of 180 to 210 Ncm corresponds to a bearing preload of 0.12 to 0.16mm. Ev-En-B=0.12 to 0.16mm Twice use of collapsible spacer is not permitted(Permanent deformation).

4.	Assemble the O-ring and select the proper spacer later when reassembling the transfer case.