Center Case
ASSEMBLYOil Filter
1. Apply ATE or petroleum jelly to new O-ring, and install it to oil filter stud.
- Do not reuse O-rings.
2. Install oil filter stud to center case, and tighten it.
25 - 35 Nm (2.6 - 3.6 kg-m, 19 - 26 ft. lbs.)
3. Apply ATE or petroleum jelly to two new O-rings, and install them to oil filter.
- Do not reuse O-rings.
4. Install oil filter to center case and tighten bolts.
7 - 9 Nm (0.7 - 0.9 kg-m, 61 - 78 inch lbs.)
- Do not knock oil filter with a tool such as a hammer.
Sub-oil Pump
1. Install new oil pump gasket to center case by aligning it with dowel pin inside the center case.
- Do not reuse gaskets.
2. Install outer gear* and inner gear to sub-oil pump housing, and measure side clearance.
3. Set new O-ring to sub-oil pump housing, and install sub-oil pump cover.
- Do not reuse O-rings.
Identification mark "of" is placed on the side of sub-oil pump cover.
4. Align dowel pin hole and mounting bolt hole of sub-oil pump assembly with center case. Then tighten bolts.
7 - 9 Nm (0.7 - 0.9 kg-m, 61 - 78 inch lbs.)
5. Apply ATF or petroleum jelly to new O-ring and install it to transfer motor.
6. Fit double-flat end of transfer motor shaft into slot of sub-oil pump assembly. Then tighten bolts.
41 - 48 Nm (4.2 - 4.9 kg-m, 30 - 35 ft. lbs.)
Main Oil Pump
1. Install inner gear and outer gear in the main oil pump housing with their identification marks facing toward center case mounting surface side. Then, measure the side clearance.
2. Install main oil pump assembly to center case assembly, and tighten bolts.
7 - 9 Nm (0.7 - 0.9 kg-m, 61 - 78 inch lbs.)
3. Install oil pump shaft to main oil pump, then install rear case assembly to center case.
Control Valve
1. Clean upper body, control valves and springs with cleaning agent, and apply air blow.
2. Dip control valves in ATF, and apply ATF to the valve-mounting area of upper body.
3. Install each control valve, spring, and plug to upper body, and fix it with retainer plates.
CAUTION:
- To insert control valves into upper body, place upper body on a level surface in order to prevent flaw or damage.
- Make sure each control valve is smoothly inserted.
4. Install reverse balls, relief balls and relief springs, accumulator pistons, valve springs and two filters to upper body.
5. Install lower body and separator plate to upper body
- Do not reuse separator plates.
6. With lower body down, tighten two bolts in the position shown in the figure.
7. Apply ATF or petroleum jelly to new O-ring, and install it to 2-4WD shift solenoid valve, terminal body, line pressure switch and 4WD solenoid valve. Install them to control valve assembly.
- Do not reuse O-rings.
8. Apply ATF or petroleum jelly to lip seals, and install them to center case.
- Do not reuse lip seals.
- There are 2 kinds of lip seals (lip seal of large inner diameter: 5 pieces, lip seal of small inner diameter: 2 pieces). Confirm the position before installation.
9. Install bolts as shown in the figure, and tighten them to specified torque.
Tighten with oil strainer.
10. Install control valve assembly to center case, and tighten bolts.
6.9 - 8.8 Nm (0.70 - 0.90 kg-m, 61.1 - 77.9 inch lbs.)
11. Secure terminal body with snap ring.
12. Apply ATF or petroleum jelly to O-rings, and install them to oil strainer.
CAUTION: Do not reuse snap ring.
13. Install oil strainer to control valve assembly.
14. Install mainshaft and clutch drum to center case.
15. Install front case assembly and rear case assembly.
Clutch Piston
1. Apply ATF to D-ring and lip seal, and install them to clutch piston.
2. Set clutch piston to a clutch piston attachment (KV31103400).
3. Set the clutch piston attachment to center case, and install clutch piston, tap it lightly.
4. Install slide needle bearing race to clutch piston.
5. Remove all the liquid gasket from oil pressure check port and inside center case. With oil pressure check plug threaded in 1 or 2 pitches, apply Genuine Thread Sealant or equivalent to the thread of plug, and tighten.
10 - 17 Nm (1.0 - 1.7 kg-m, 87 - 148 inch lbs.)
6. Install mainshaft and clutch drum.
Mainshaft and Clutch Drum
1. Install drive plates, driven plates and press flange to clutch hub.
2. Place clutch hub on a surface plate and measure dimension "A" between snap ring mounting surface of press flange and clutch drum sliding face of clutch hub.
CAUTION: Measure at least 2 points, and take an average.
3. Measure dimension "B" between the gear end of mainshaft and the snap ring mounting portion.
4. Calculate end play using dimension "A" and dimension "B" (obtained in steps 2 and 3), and select proper retaining plate so that the end play is within specifications.
Calculation formula: End play = B - A - Retaining plate thickness
Standard end play: 0.2 - 0.5 mm (0.008 - 0.020 inch)
5. Install clutch drum, needle bearing and clutch hub to mainshaft, and secure them with snap ring.
- Do not reuse snap ring.
6. Install each clutch to clutch drum.
7. Align the notch of return spring assembly with the pin of clutch hub, and install it.
8. Install press flange (with the holes indicated by arrows aligned with pins of clutch hub).
9. Install washer.
10. Pass mainshaft through snap ring. Set a drift (KV31103300), a support ring (KV40104710), a support ring (ST27863000) and a drift (ST35271000) to press flange at the position shown in the figure, and press snap ring until it fits into snap ring groove on mainshaft.
- Do not reuse snap ring.
11. Fix snap ring to mainshaft.
12. Install thrust needle bearing to press flange.
13. Apply petroleum jelly to new seal rings, and install them to mainshaft. Measure clearance between seal ring and groove using feeler gauge.
Standard clearance: 0.05 - 0.30 mm (0.0020 - 0.0118 inch)
Limit clearance: 0.30 mm (0.0118 inch)
- Pass seal ring from mainshaft rear end to install it.
14. Install mainshaft rear bearing to center case.
15. Place puller (ST30911000) to mainshaft rear bearing inner race, and set it to press stand.
16. Place adapter (ST33061000) to the tip of mainshaft, and press mainshaft into center case.
17. Install baffle plate to center case, and tighten bolts.
3.7 - 5.0 Nm (0.38 - 0.51 kg-m, 33.0 - 44.3 inch lbs.)
18. Install front drive shaft and drive chain. Refer to "Front Drive Shaft and Drive Chain" below.
19. Install front case assembly and rear case assembly.
Front Drive Shaft and Drive Chain
1. Place a base (ST30032000) to front drive shaft rear bearing inner race, and press it using a drift (KV40100621).
2. Place base (ST30032000) to front drive shaft front bearing inner race, and press it using the drift (KV40100621).
3. Install drive chain temporarily to front drive shaft and drive gear of clutch drum.
4. Tap front drive shaft with a plastic hammer while keeping it upright and press-fit front drive shaft rear bearing. Be careful not to tap drive chain with a hammer.
5. Align claw of oil gutter with center case, and install it.
6. Install front case assembly and rear case assembly.