Reassembly of External Parts
MAJOR COMPONENT:TRANSMISSION AND TRANSFER CASE ASSEMBLY
Reassembly Steps
1. Transmission and transfer assembly
! 2. Transfer rear case assembly
! 3. Counter gear snap ring
! 4. Bearing snap ring
! 5. Front cover with oil seal
! 6. Transfer flange
7. Speedometer driven gear
Important Operations
NOTE: Details of the service procedure are provided for "Important Operations" only, marked with "!" above. Pay close attention to these steps.
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: kg-m(lb-ft/N-m)
3.8 ± 0.8 (27.5 ± 7.8/37.2 ± 7.8)
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: kg-m(lb-ft/N-m)
1.9 (13.7/18.6)
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: kg-m(lb-ft/N-m)
14 (101.3/137.2)
Key to Major Parts
Tighten to specified torque. Units shown are measured as: kg-m (lb.ft)