Reassembly of External Parts

REASSEMBLY OF EXTERNAL PARTS




MAJOR COMPONENTS

Important Operations




2. Transfer Rear Case Assembly
1. Apply recommended liquid gasket or its equivalent to the transfer rear case fitting faces.




2. Apply the following steps before fitting the transfer rear case.
1. Shift the High-Low synchronizer to the 4H side.
2. Turn the select rod counterclockwise so that the select block projection (A) may enter into the 2WD-4WD shift block.




When the rear case is fitted under this condition (2), the direction of the cut-away portion of select rod head (B) aligns with that of the rear case hole's stopper (C)

3. Tighten the rear transfer rear case bolts to the specified torque.

Transfer Case Bolt Torque: 3.8 ± 0.8 (27.5 ± 7.8/37.2 ± 7.8) kg.m (lb.ft/N.m)




3. Counter Gear Snap Ring
4. Bearing Snap Ring
Use a pair of snap ring pliers to install the snap ring to the mainshaft.
The snap ring must be fully inserted into the ball bearing snap ring groove.




5. Front Cover with Oil Seal
1. Apply recommended liquid gasket or its equivalent to the through bolt threads.
2. Install the front cover with oil seal to the transmission case.
Take care not to damage the oil seal.
3. Tighten the front cover bolts to the specified torque.

Front Cover Bolt Torque: 1.9 (13.7/18.6) kg.m (lb.ft/N.m)




6. Transfer Flange
1. Use the flange holder to install the flange to the rear transfer case.
Flange Holder : J-27221
2. Tighten the transfer flange bolts to the specified torque.

Transfer Flange Bolt Torque: 14 (101.3/137.2) kg.m (lb.ft/N.m)