Repair procedures (M5GF2)

Removal

NOTE:
1. The repair of the transfer assembly requires a special skill and furthermore an improper adjustment of the spacers may cause a severe noise and durability issue.
2. Hypoid gear set is manufactured and controlled as a pair. Any replacement of the part is to be done as a pair, hypoid gear shaft assembly (47308-39200) and pinion shaft (47311-39000).

1. Remove the battery negative (-) cable.
2. Disconnect the oxygen sensor connector(A,B) and remove the oxygen sensor connector wire clamp from a bracket. (Engine room right side).




3. Remove the wheel and tire (Right side).
4. Remove the engine side cover(A) (Right side).
5. Remove the drive shaft(A) from the transfer(see DS group).
6. Remove the front exhaust muffler assembly(A).




7. Drain the transfer oil through drain plug hole.
8. Remove the pinion case mounting bolts(A-4ea).




9. Remove the heat protector(A) using a hexagonal socket.
1.
NOTE:
To remove the heat protector mounting bolt easily, before removing the heat protector mounting bolts(3EA), apply the mounting bolt with "WD-40 stops squeaks".




2. Lift up the vehicle.
3. Remove the exhaust manifold mounting nuts(7EA).

NOTE:
To remove the exhaust manifold mounting nut easily, before removing the exhaust manifold mounting nuts(7EA), apply the mounting nuts with "WD-40 stops squeaks".

4. Remove the transfer mounting bracket.
5. Remove the transfer mounting bolts(4EA).
6. Using a flat head screw driver, remove the transfer from the transaxle by moving the driver to left and right directions.

Installation

1. Temporarily install the transfer assembly to the transaxle.

NOTE:
To install the transfer easily, install it by moving the pinion left and right directions, and slightly rotating the inner drive shaft of transfer assembly.

2. Install the transfer mounting bolts(4EA).

Tightening torque :
62 - 67 Nm(6.2 - 6.7 kgf.m, 44.8 - 48.5 lb-ft)


3. Install the transfer mounting bracket.

Tightening torque :
47 - 51 Nm(4.7 - 5.1 kgf.m, 34.0 - 36.9 lb-ft) - 2EA
24 - 28 Nm(2.4 - 2.8 kgf.m, 17.4 - 20.3 lb-ft) - 2EA


4. Tighten the exhaust manifold mounting nuts(7EA).

Tightening torque :
30 - 35 Nm(3.0 - 3.5 kgf.m, 21.7 - 25.3 lb-ft)


5. Tighten the heat protector(A) mounting nuts(3EA).

Tightening torque :
11.8 - 14.7 Nm(1.2 - 1.5 kgf.m, 8.7 - 10.8 lb-ft)





6. Tighten the pinion case mounting bolts(A-6ea).

Tightening torque :
37 - 40 Nm(3.7 - 4.0 kgf.m, 14.5 - 21.7 lb-ft)





7. Refill the transfer oil through the filler plug.
8. Install the front exhaust muffler assembly(A).




9. Install the drive shaft(RH) to the transfer assembly, lower arm ball joint mounting and steering bar tie rod ball joint.
10. Lower the vehicle down.
11. Install the engine side cover (RH) and the wheel and tire(RH).
12. Install the oxygen sensor connector bracket and connect the oxygen sensor connector(A,B). (Engine room right side).




13. Install the air intake hose and air cleaner cover and then connect the oxygen sensor connector.(A-Engine room left side).
14. Connect the battery negative (-) cable.