Transfer System: Precaution

Before disassembly, clean the transfer assembly and remove any deposited sand and mud to prevent it from entering the transfer during disassembly and assembly.
When removing any light alloy parts such as the transfer covers, do not pry them off with a tool like a screwdriver, but tap them out with a plastic hammer.
Always organize the removed parts properly and protect them from dust.
After cleaning and drying the transfer completely before installation, apply hypoid gear oil to each part. Do not use alkaline chemicals when cleansing aluminum or rubber parts or ring gear set bolts. Also, do not use any cleansing oil (ex. white gasoline) to clean rubber parts such as oil seals.
Apply sufficient hypoid gear oil to all sliding surfaces and rotating parts.
Do not directly hold any parts in a vise. Be sure to put an aluminum sheet between them.
Replace any damaged or deformed snap rings with new ones.
If the mating surface of the case is scratched, it could cause oil leakage. Therefore, handle with care to prevent such damage.
Using a razor blade and gasket scraper, remove old FIPG from the seal surface.
Clean all the components to remove the redundant FIPG completely.
Clean the sealing surface with solvent so that no residue remains on the seal surface.
Apply a line of FIPG approximately 1.2 mm (0.047 in.) diameter of bead state along the sealing surface.
Be sure to assemble parts within 10 minutes of application. Otherwise, the FIPG must be removed and reapplied.
Do not pour in oil immediately after installing sealed parts. Leave it for at least an hour.
Scratches on the contact surface with an oil seal or gasket could cause oil leakage. Handle with care to prevent such damage.
When press-fitting an oil seal, take care to prevent the oil seal lip and its periphery from being damaged.
When servicing or disconnecting the 4WD ECU, be sure to disconnect all power by removing the 20A 4WD fuse or the negative battery terminal. Failure to disconnect power for the 4WD ECU before performing Repair Manual diagnostic procedures may cause the transfer case actuator to be activated, resulting in damage to the transfer case actuator.