Assembly
REASSEMBLYTransfer Side Case:
MINOR COMPONENTS
Important operations
1. Front output shaft rear bearing
Install the front output shaft rear bearing into position deep enough to touch snap ring.
Bearing remover and installer : J-29040
Grip : J-8092
2. Output gear
Install the output gear, so that its end without splines (on inner circumference) is turned toward front side (toward output shaft flange).
3. Front output shaft front bearing
Drive the output shaft front bearing into position to touch output gear.
Bearing remover and installer : J-29040
Grip : J-8092
4. Output shaft oil seal
Installer : J-29037
Grip : J-8092
5. Front output shaft
Wrench : J-8614-01
Torque: 14 - 16 (101 - 116) (kg-m (ft-lbs.))
7. Front output shaft cover
Torque: 2.5 - 3.1 (18 - 22) (kg-m (ft-lbs.))
8., 10. Thrust washer
Apply grease to both faces of the idler gear thrust washer, then install the thrust washer, with the oil grooved face turned toward the gear, by aligning the stopper finger with the groove in the case.
11. Idler gear shaft
Coat the idler shaft O-ring with clean engine oil and install the idler gear shaft by aligning the dowel groove in the idler shaft with the dowel pin hole.
12. Dowel pin
Insert the dowel pin into the case and check that its projection is within the specified value.
Projection: 9 - 11 (0.355 - 0.433) (mm (in.))
14. High/Low shift rod
Attach the range shift arm so that the slit in the spring pin is turned.
Attach and secure the shift arm shift rod in position with the spring pin.
15. 4x2/4x4 shift arm and shift block
Assemble the shift arm with the shift block, then attach the gear look release spring.
16. 4x2/4x4 shift rod
Insert the interlock pin, the shift rod detent ball and the detent spring in the case.
Insert and secure the shift arm, the shift block and the shift rod in position with the spring pin.
17., 18. Screw Plug
Screw plug torque: 4.5 - 5.5 (33 - 40) (kg-m (ft-lbs.))
Transfer Case:
MINOR COMPONENTS
Important Operations
1. 4x2/4x4 sleeve
Attach the 4x2/4x4 sleeve so that the side with the chamfering is turned rearward.
4. Thrust washer
Attach the thrust washer so that the side with the oil groove is turned forward.
1 Oil groove
5. Ball bearing
Attach the output shaft front bearing to the output shaft so that the snap ring groove is turned to the rear.
Installer : J-22912-01
9. Ball bearing
Press the output shaft rear bearing into position with the face seal turned to the rear.
Installer: J-22912-01
10. Nut
Nut hex : 41 mm (1-5/8 in.)
Torque: 14 - 16 (101 - 116) (kg-m (ft-lbs.))
11. Output shaft assembly
Insert the snap ring on the transfer case into the groove in the output shaft front bearing.
18. Counter shaft assembly
Install the counter shaft assembly in the case, so that the cutaway portion at front end of the counter shaft is turned in the direction shown in the figure.
19. High/Low sleeve
Install the range shaft sleeve on the output shaft, so that the end of the sleeve with the heavy chamfering on the outer circumference is turned toward the front
Main shaft gear assembly, cluster gear assembly and top gear shaft assembly.:
MINOR COMPONENTS
Reassembly steps
1. Shaft ; main
2. Bearing ; needle, 2nd, 3rd
3. Gear assembly; 2nd with synchronizer cone *
4. Ring ; block, low-2nd
5. Synchronizer assembly; low-2nd *
6. Ring; block, low-2nd
7. Collar; needle bearing, low *
8. Bearing ; needle, low
9. Gear assembly; low with synchronizer cone
10. Washer ; thrust, low *
11. Bearing ; radial ball, main shaft *
12. Washer; thrust, reverse *
13. Collar; needle bearing, reverse *
14. Bearing ; needle, 2nd, 3rd
15. Gear assembly ; 3rd with synchronizer cone
16. Ring ; block, top-3rd
17. Synchronizer assembly; top-3rd *
18. Ring ; snap, main shaft *
19. Ring; block, top-3rd
20. Bearing ; needle, main shaft
21. Bearing ; ball top gear shaft *
22. Ring ; snap, bearing to top gear shaft
23. Shaft; top gear, with synchronizer cone
24. Bearing ; ball counter front
25. Ring snap, cluster gear
26. Gear; cluster
27. Bearing ; angular ball, cluster *
28. Gear; counter reverse
29. Shaft; reverse idle *
30. Ring ; snap, main shaft
31. Ring ; snap, cluster gear
32. Plate; intermediate *
33. Washer; thrust, reverse idle, front
34. Gear; reverse idle, with busing
35. Washer; thrust, reverse idle, rear
36. Nut; self lock, counter *
37. Bearing ; needle, low
38. Gear ; reverse, main shaft
39. Synchronizer assembly ; reverse-5th *
40. Washer; lock, main shaft
41. Nut; main shaft *
42. Ring; block, 5th
43. Gear assembly; 5th with synchronizer cone
44. Bearing ; needle, 5th
45. Washer; thrust, 5th *
46. Thrust ring ; 5th gear
47. Ring ; snap, thrust ring *
48. Retaining ring
49. Ring ; snap, ball bearing
50. Gear; counter, 5th
51. Bearing ; ball, counter end
52. Washer ; plain, counter 5th gear
53. Nut; self lock, counter *
54. Adapter case
55. Oil guide
56. Bolt; oil guide
57. Bearing; roller main shaft center
58. Ring ; snap adapter case
59. Ring ; snap
60. Collar thrust input gear
61. Collar; needle bearing
62. Thrust input gear
63. Thrust input hub
64. Nut; thrust input hub *
65. Pin and plug interlock
66. Fork; low-2nd, shift
67. Shaft; arm, gear shift, top-3rd *
68. Fork; top-3rd, shift A 69. Shaft; arm, gear shift, low-2nd
70. Fork; reverse-5th, shift
71. Shaft; arm, gear shift, reverse-5th *
72. Ball; detent, gear shift
73. Spring ; detent ball *
74. Plate; detent spring *
* Important Operations
Important operations
3. Gear assembly ; 2nd with synchronizer cone
Taper cone face of the second gear should be turned to the low gear side (rear).
5. Synchronizer assembly ; low-2nd
1. When reassembling the synchronizer assembly, the side of the clutch hub with the oil groove must face the heavy chamfer of the sleeve.
2. Check that the inserts are fitted properly into the insert grooves in the blocker ring and that the insert spring is fitted to the insert keys as shown in this figure. Then check that the clutch hub and sleeve slide smoothly.
3. Install the synchronizer assembly on the shaft, so that face of sleeve with light chamfer on the outer edge is turned to the front of transmission.
(1) : Insert key
(2) : Insert spring
(3) : Clutch hub
7. Collar ; needle bearing, low
Use a bench press.
Installer : J-33851
10. Washer ; thrust, low
Install the thrust washer, so that its side with oil groove (1) is turned forward.
11. Bearing ; radial ball, main shaft
Set the main shaft ball bearing to the separator, so that its face with snap ring groove is turned to the front of transmission, then install the bearing on the shaft using a bench press.
(1) ; Snap ring groove
Installer : J-22912-01
12. Washer ; thrust, reverse
Install the thrust washer, so that its side with oil groove (1) is toward the rear.
13. Collar ; needle bearing, reverse
Use a bench press.
Installer : J-33851
17. Synchronizer assembly ; top-3rd
When reassembling the synchronizer assembly, the side of the hub with the higher boss must face the light chamfer of the sleeve.
18. Ring ; snap, main shaft
Clearance between top/3rd clutch hub and snap ring.
Standard: 0 - 0.05 (0 - 0.0019) (mm (in.))
21. Bearing; ball, top gear shaft
Install the top gear shaft ball bearing, so that the side with snap ring groove is turned to front.
(1); Snap ring groove
Installer : J-22912-01
27. Bearing ; angular ball, cluster
Install the cluster gear rear bearing, so that the side with snap ring groove is turned rearward.
(1); Snap groove
Installer : J-22912-01
29. Shaft ; reverse idle
Torque: 1.8 - 2.2 (13 - 16) (kg-m (lbs.))
32. Plate ; intermediate
Mesh the countergear with the mainshaft assembly and attach Tool J-29768 to the mainshaft and the countergear.
Place Tool J-29768 with the mainshaft and countergear assembled in a vise, then install the intermediate plate.
Engage the Top/3rd and Low/2nd synchronizers with the 3rd and Low gears, then attach and tighten the lock nuts to the specified torque as follows.
36. Nut ; self lock, counter
Torque: 10 - 12 (72 - 87) (kg-m (ft-lbs.))
Discard the used nut and install new one at reassembly.
39. Synchronizer assembly ; reverse-5th
When reassembling the synchronizer assembly, the side of the clutch hub with higher boss must face the heavy chamfer of the sleeve. The shorter shoulder side of the insert should be on the same side.
(1) ; Shorter shoulder side
(2) ; Heavy chamfering
41. Nut ; main shaft
Lock the nut with lock washer after tightening it to the specified torque.
Wrench : J-33441
Torque: 12 - 14 (87 - 101) (kg-m (ft-lbs.))
Thicknesses Of Thrust Washers Available.:
45. Washer thrust, 5th
Install the lock ball and thrust washer on the mainshaft using a snap ring.
Clearance between 5th gear and thrust washer.
Standard: 0.10 - 0.30 (0.004 - 0.012) (mm (in.))
47. Ring ; snap, thrust ring
The opening of the snap ring should be positioned at right angle to opening of the thrust ring.
53. Nut
Torque: 10 - 12 (72 - 87) (kg-m (ft-lbs.))
64. Nut ; thrust input hub
Wrench : J-33441
67. Shaft; arm, gear shift, top-3rd
69. Shaft arm, gear shaft. low-2nd
71. Shaft arm. gear shift reverse-5th
When installing spring pin, hold a round bar against lower face of shift rod end to protect it against damage.
Discard used spring pin and install a new one at reassembly.
73. Spring ; detent ball
The detent spring for Rev./5th is shorter in length when compared with those for Low/2nd and Top/3rd.
74. Plate ; detent spring
Torque: 1.8 - 2.2 (13 - 16) (kg-m (ft-lbs.))
MAJOR COMPONENTS
Important operations
2. Transfer case
Installation of transfer case rear oil seal.
Installer : J-29769
Tighten evenly the four bolts holding the transfer case and intermediate plate.
Push the transfer counter shaft assembly into the transfer case measure the distance between the rear face of the transfer case and end of the transfer countershaft and select the distance piece by referring to the table.
5. Belleville spring
Install the belleville spring with dished side turned to bearing as illustrated in the drawing.
6. Front cover
Install the front cover oil seal.
Setting tool : J-26540
Torque: 1.5 - 2.3 (10.8 - 16.6) (kg-m (ft-lbs.))
Apply adhesive (Permatex No.2 or equivalent) to the threaded portion of the through bolt on the left lower side of the transmission case (as viewed from front side of the case) before installation.
8. Shift block
Apply grease to the inner face of the shift block.
Check that hook on the withdraw lever is fitted to the support properly.