Part 1
ASSEMBLYCenter Case
1. Apply [1][2]ATF to the new O-ring, and install it on the oil filter stud.
CAUTION: Do not reuse O-rings.
2. Install the oil filter stud to the oil filter.
3. Apply [1][2]ATF to the two new O-rings (1), and install them on the oil filter (2).
CAUTION: Do not reuse O-rings.
4. Install the oil filter to the center case. Tighten the bolts to the specified torque.
CAUTION:
^ Do not damage oil filter.
^ Attach oil filter and tighten bolts evenly.
5. Install the outer gear and inner gear into the sub oil pump housing, and measure the side clearance.
6. Align the dowel pin hole and bolt hole of the sub oil pump assembly with the center case. Install the sub oil pump cover. Then tighten to the specified torque.
7. Apply [1][2]ATF to the new O-ring and install it to the transfer motor.
CAUTION: Do not reuse O-rings.
8. Fit the double-flat end of the transfer motor shaft into the slot of the sub-oil pump assembly. Then tighten to the specified torque.
CAUTION: Be sure to install connector bracket.
9. Assemble the control valve assembly with the following procedure
CAUTION:
^ Do not reuse any part that has been dropped or damaged.
^ Make sure valve is assembled in the proper direction.
^ Do not use a magnet because residual magnetism stays during assembly.
a. Clean the upper body (5), control valves (3) and springs (4) with cleaning agent, and dry with compressed air.
b. Dip the control valves in [1][2]ATF, and apply ATF to the valve-mounting area of the upper body
c. Install each control valve (3), springs (4), and plugs (2) to the upper body (5), and install retainer plates (1) to hold them in place.
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.
d. Install the reverse balls, relief balls and relief springs, accumulator pistons and valve springs to the upper body
e. Install the lower body and separator plate to the upper body.
CAUTION: Do not reuse separator plates.
f. With the lower body down, tighten the two bolts shown.
g. Apply [1][2]ATF to the new O-rings, and install them to each solenoid valve, switch and terminal body.
CAUTION: Do not reuse O-rings.
h. Install the following to the control valve assembly:
^ Clutch pressure solenoid valve
^ Clutch pressure switch
^ 2-4WD shift solenoid valve
^ Line pressure switch
^ Transfer fluid temperature sensor
10. Apply [1][2]ATF to the new lip seals, and install them to the center case.
CAUTION:
^ 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 their position for installation.
11. Install the control valve assembly to the center case, and tighten to the specified torque.
CAUTION:
^ Do not reuse any part that has been dropped or damaged.
^ Make sure valve is assembled in the proper direction.
^ Do not use a magnet because residual magnetism stays during assembly.
12. Install the connector assembly into the center case, and secure with a snap ring.
13. Apply [1][2]ATF to the new O-rings, and install them on the oil strainer.
CAUTION: Do not reuse O-rings.
14. Install the oil strainer to the control valve assembly.
15. Tighten the bolts to the specified torque.
16. Apply [1][2]ATF to the new D-rings, and install them to the clutch piston.
CAUTION: Do not reuse D-rings.
17. Install the thrust needle bearing race to the clutch piston.
18. Install the clutch piston to the center case as shown.
CAUTION: Install so the fitting protrusion of clutch piston aligns with the dent of center case.
19. Remove all the sealant from the oil pressure check port and inside the center case.
CAUTION: Remove old sealant adhering to mating surfaces. Also remove any moisture, oil, or foreign material adhering to application and mating surfaces.
20. Thread the new oil pressure check plug in 1 or 2 pitches and apply sealant to the oil pressure check plug threads. Tighten to the specified torque.
^ Use Genuine Silicone RTV or equivalent.
CAUTION: Do not reuse oil pressure check plug.
21. Install the new snap ring to the clutch hub using suitable tool.
CAUTION: Do not reuse snap ring.
22. Apply petroleum jelly to the needle bearing, and install the needle bearing, spacer, clutch drum and clutch hub to the mainshaft.
23. Install the new snap ring to the mainshaft.
CAUTION: Do not reuse snap rings.
24. Apply [1][2]ATF each plate, then install them into the clutch drum as shown.
25. Install the return spring assembly into the clutch hub.
26. Install the press flange by aligning the notches to the clutch hub as shown.
27. Press the press flange to install the new snap ring into snap ring groove on mainshaft using Tools.
Tool number
A: ST22452000 (J-34335)
B: ST30911000 ( - )
C: KV31103300 ( - )
CAUTION: Do not reuse snap ring.
28. Install the new snap ring to the mainshaft using suitable tool.
CAUTION: Do not reuse snap ring.
29. Apply [1][2]ATF to the thrust needle bearing and install it on the press flange.
30. Install the new snap ring to the main shaft.
CAUTION: Do not reuse snap ring.
31. Install the mainshaft rear bearing to the center case using Tool.
Tool number: ST15310000 (J-25640-B)
32. Install the mainshaft assembly using a press.
^ Press the mainshaft into the center case using Tools.
Tool number
A: ST30911000 ( - )
B: ST33052000 ( - )
33. Install the C-rings to the mainshaft.
34. Set the washer holder on the mainshaft, and secure it with a new snap ring.
CAUTION: Do not reuse snap ring.
35. Apply petroleum jelly to the stem bleeder and install it to the center case.
36. Apply [1][2]ATF to the new seal ring and install it to the main oil pump cover.
CAUTION: Do not reuse seal ring.
37. Install the inner gear and outer gear in the main oil pump housing. Then, measure the side clearance. Refer to DLN-176, "Inspection and Adjustment". Inspection and Adjustment
38. Install the main oil pump housing, outer gear and inner gear to the center case.
39. Install the main oil pump cover to the center case, and tighten to the specified torque.
40. Remove all the sealant from the switch location area and inside the center case.
CAUTION: Remove old sealant adhering to mounting surfaces. Also remove any moisture, oil, or foreign material adhering to application and mounting surfaces.
41. Thread the ATP switch and NEUTRAL-4LO switch in one to two pitches and apply sealant to the threads of the switches. Tighten to the specified torque.
^ Use Genuine Silicone RTV or equivalent.
NOTE:
^ NEUTRAL-4LO switch harness connector is gray.
^ ATP switch harness connector is black.
42. Install the front drive shaft rear bearing using Tools.
Tool number
A: KV40100621 (J-25273)
B: ST30032000 (J-26010-01)
43. Install the front drive shaft to the front bearing using Tools.
Tool number
A: KV40100621 (J-25273)
B: ST30032000 (J-26010-01)
44. Install the drive chain to the front drive shaft and clutch drum.
CAUTION: Install drive chain by aligning identification marks to the rear as shown.
45. Tap the front drive shaft while keeping it upright and press-fit the front drive shaft rear bearing.
CAUTION: Do not tap drive chain.
46. Install the front case assembly.
47. Install the rear case assembly.