Reassembly
REASSEMBLY OF INTERNAL PARTS MAJOR COMPONENT (TRANSMISSION)
MAJOR COMPONENT (TRANSFER CASE)
REASSEMBLY - MINOR COMPONENTS - INTERMEDIATE PLATE AND GEAR ASSEMBLY TOP GEAR SHAFT, MAIN SHAFT GEAR AND COUNTER GEAR
Important Operations
2. Needle Bearing
3. 2nd Gear
1) Apply engine oil to the needle bearing and the 2nd gear thrust surfaces.
2) Install the needle bearing and the 2nd gear to the mainshaft. The dog teeth of the 2nd gear must be facing the rear side of the transmission.
7. 1st-2nd Synchronizer Assembly
1) Turn the clutch hub dished face (1) toward the sleeve small groove (2) on the outer circumference.
2) Check that the inserts (3) fit snugly into the block ring insert grooves.
3) Check that the insert springs (4) are fitted to the inserts as shown in the illustration.
4) Check that the clutch hub (5) and the sleeve (6) slide smoothly.
5) Install the synchronizer assembly to the mainshaft. The clutch hub face (with the heavy boss) must be facing the 2nd gear side.
8. Clutch Hub Snap Ring
1) Select the snap ring which will provide the minimum clearance between the 1st/2nd clutch hub and the snap ring. There are three snap ring sizes available. The snap rings are color-coded to indicate their thickness.
2) Use a pair of snap ring pliers to install the snap ring to the mainshaft.
The snap ring must be fully inserted into the mainshaft snap ring groove.
9. Needle Bearing
13. 1st Gear
1) Apply engine oil to the needle bearing and the 1st gear thrust surfaces.
2) Install the needle bearing and the 1st gear to the mainshaft.
The 1st gear dog teeth must be facing the transmission front side.
14. 1st Gear Thrust Bearing - Install the thrust bearing to the mainshaft. The thrust bearing side must be facing the transmission front side.
15. Mainshaft Ball Bearing
16. Needle Bearing Collar
1) Apply engine oil to the ball bearing and the mainshaft.
2) Install the ball bearing and collar to the mainshaft. The ball bearing snap ring groove must be facing the transmission rear side.
3) Use a bench press to slowly force the collar into place. Installer: J-613301
17. Needle Bearing
18. 3rd Gear
1) Apply engine oil to the needle bearing and the 3rd gear thrust surfaces.
2) Install the needle bearing and the 3rd gear to the mainshaft.
The dog teeth of the 3rd gear must be facing the front side of the transmission.
20. 3rd-4th Synchronizer Assembly
1) Turn the clutch hub face (1) with the heavy boss (A) toward the sleeve small groove (2) on the outer circumference.
2) Check that the inserts (3) fit snugly into the block ring insert grooves.
3) Check that the insert springs (4) are fined to the inserts as shown in the illustration.
4) Check that the clutch hub (5) and the sleeve (6) slide smoothly.
5) Install the synchronizer assembly to the mainshaft. The clutch hub face (with the heavy boss) must be facing the 3rd gear side.
21. Mainshaft Snap Ring
1) Select the snap ring which will provide the minimum clearance between the 3rd-4th clutch hub and the snap ring.
There are three snap ring sizes available.
The snap rings are color-coded to indicate their thickness.
2) Use a pair of snap ring pliers to install the snap ring to the mainshaft. The snap ring must be fully inserted into the main- shaft snap ring groove.
25. Ball Bearing
26. Top Gear Shaft Snap Ring
1) Use a bench press to install the top gear shaft ball bearing to the mainshaft. The snap ring groove must be facing the transmission front side.
2) Use a pair of snap ring pliers to install the snap ring to the bearing.
28. Front Roller Bearing
1) Apply engine oil to the bearing and install the inner race (1) and outer race with roller in the proper direction to the mainshaft.
2) Then install the inner race (3) with taper side turned to outer race (2). Install the inner race (3) with its marked face directing toward the front of transmission.
REVERSE GEAR AND 5TH GEAR
Important Operations
1. Intermediate Plate
1) Mesh the counter gear with the mainshaft assembly.
2) Install the holding fixture to the mainshaft and the counter gear. Holding Fixture : J-37224 Holding base -3289-20
3) Place the holding fixture (with the mainshaft and the counter shaft) in a vise.
4) Install the intermediate plate.
3. Bearing Plate and screw
1) Apply recommended thread locking agents or its equivalent to each of the plate screw threads.
2) Use the wrench to tighten the screws to the specified torque. Torx Bit Wrench J-37225 (T45)
Plate Screw Torque: 1.5 (10.8/14.7) kg.m (lb.ft/N.m)
7. Rev.-5th Synchronizer Assembly
1) Turn the clutch hub face (1) toward the sleeve small groove (2) on the outer circumference.
2) Check that the inserts (2) fit snugly into the block ring insert grooves.
3) Check that the insert springs (4) are fitted to the inserts as shown in the illustration.
4) Check that the clutch hub (5) and the sleeve (6) slide smoothly.
5) Install the synchronizer assembly to the mainshaft. The clutch hub face (with the heavy boss) must be facing the reverse gear side.
The clutch hub groove (A) must be aligned with the key groove of sleeve.
8. Clutch Hub Nut
1) Mesh the 1st-2nd synchronizer with both the 1st and 3rd gears (double engagement). This will prevent the mainshaft from turning.
2) Install the mainshaft lock nut.
3) Use the lock nut wrench to tighten the lock nut to the specified torque. Wrench: J-37219
Hub Nut Torque: 14 ± 12 (101.0 ± 14.2/137.2 ± 19.6) kg.m (lb.ft/N.m)
4) Use a punch to stake the lock nut.
12. Counter Reverse Gear
1) Apply engine oil to the counter reverse gear and the reverse gear.
2) Install the counter reverse gear to the counter gear. The reverse gear projection must be facing the side of the intermediate plate.
Ball Bearing and Snap Ring Clearance
Snap Ring Availability mm(in)
Thickness / Color Coding
1)1 (0.071) White
1)2 (0.073) Yellow
1)3 (0.075) Blue
1)4 (0.055) Pink
1)5 (0.059) Green
1)6 (0.063) Brown
There are six snap ring sizes available.
The snap rings are color-coded to to indicate their thickness
15. Bearing Snap Ring
Standard 0-0.15 (0 - 0.0059) mm(in)
1) Select the snap ring which will provide the minimum clearance between the ball bearing and the snap ring.
2) Use a pair of snap ring pliers to install the snap ring to the mainshaft. The snap ring must be fully inserted into the counter 5th gear snap ring groove.
19. Thrust washer
Install the thrust washer with the oil grooved side toward the reverse idler gear.
21. Reverse Gear Snap Ring
1) Select the snap ring which will provide the minimum clearance between the intermediate plate and the snap ring. There are three snap ring sizes available.
The snap rings are color-coded to indicate their thickness.
Intermediate Plate and Snap Ring Clearance
Standard 0-0.14 (0 - 0.0055) mm (in.)
2) Use a pair of snap ring pliers to install the snap ring to the mainshaft.
The snap ring must be fully inserted into the counter 5th gear snap ring groove.
22. Thrust Washer and Lock Ball
1) Use a thickness gauge to measure the clearance between the 5th gear and the thrust washer.
If required, replace the existing thrust washer with a new thrust washer to bring the clearance to specification.
There are four thrust washer sizes available.
The thrust washers are color-coded to indicate their thickness.
2) Apply grease to the thrust washer and the lock ball.
3) Install the thrust washer and the lock ball to the mainshaft.
25. Ball Bearing
Use the installer to install the ball bearing to the mainshaft. Installer : J-37223
DETENT, SHIFT ARM ASSEMBLY AND INTERLOCK PIN
Important Operations
2. 1st-2nd Shift Arm
3. 3rd-4th Shift Arm
Hold a round bar (1) against the shift rod end lower face (2) to protect it against damage. Install the new spring pin. Never reinstall the used spring pin.
4. 3rd-4th Shift Rod
5. Interlock pin
1) Install the interlock pin to the shift rod.
2) Install the shift rod together with the interlock pin to the intermediate plate. Do not allow the interlock pin to fall from the shift rod.
12. Detent Spring Plate
Tighten the detent spring plate bolts to the specified torque.
Detent Spring Plate Bolt Torque: 2.0 ± 0.4 (14.4 ± 2.9/19.6 ± 3.9) kg.m (lb.ft/N.m)
MINOR COMPONENT (TRANSFER CASE) TRANSFER CASE ASSEMBLY
Important Operations
1. Transfer Case
1) Cover the shaft spline with adhesive tape (1). This will prevent damage to the oil seal lip (2). Remove the tape from the output shaft after installing the transfer case.
2) Apply recommend liquid gasket or its equivalent to the transfer case fitting surfaces.
3) Tighten the transfer case bolts to the specified torque a little at a time.
Transfer Case Bolt Torque: 3.8 ± 0.8 (27.5 ± 5.8/39.24 ± 7.84) kg.m (lb.ft/N.m)
2. Transfer Counter Gear
3. Sub Gear
Apply chassis grease to the sub-gear and the counter gear thrust surfaces.
7. Bearing Inner Snap Ring
1) Select a snap ring that will allow the minimum axial play.
2) Use a pair of snap ring pliers to install the snap ring to the counter gear
16. Front Output Gear
17. Sub Gear
18. Belleville Spring
19. Spacer
Apply engine oil to the thrust surfaces of the sub-gear, the belleville spring, and the spacer.
20. Sub Gear Snap Ring
21. Bearing Collar
Use a bench press to install the needle bearing and collar together with the front output gear.
23. Bearing Snap Ring
1) Select a snap ring that will allow the minimum axial play.
2) Use a pair of snap ring pliers to install the snap ring to the output shaft
31. High-Low Synchronizer Assembly
Turn the shallow clutch hub face (1) toward the side of the sleeve with small groove (2) on the outer circumference.
The clutch hub groove (A) must be aligned with the key groove of sleeve.
Sub Gear Preload
1) Hook a length of wire over one of the sub-gear teeth.
2) Attach the other end of the wire to a spring balancer.
3) Measure the sub-gear preload.
32. Mainshaft End Lock Nut
1) Use the lock nut wrench to tighten the mainshaft end lock nut to the specified torque. Lock Nut Wrench : J-37219
Mainshaft End Lock Nut Torque: 14 ± 2 (101.0 ± 14.2/137.2 ± 19.6) kg.m (lb.ft/N.m)
2) Stake the lock nut.
33. Ball Bearing
Use the ball bearing installer to install the ball bearing. Installer: J-37223
DETENT, SHIFT FORK ASSEMBLY AND INTERLOCK PIN
Important Operations
3. High-Low Shift Rod
4. Spring Pin
1) Engage the High-Low sleeve with 4H side.
2) Install the spring pin to the shift block.
9. Interlock Pin
10. Shift Rod
1) Engage the High-Low synchronizers with 4H side and install the interlock pin (1) in proper direction.
2) Install the shift rod: 2WD-4WD (2) with the interlock pin pushed in.
12. Spring Pin
1) Engage the 2WD-4WD sleeve with the 4WD side and install the spring pin.
11. Switch (4WD)
Tighten the switch to the specified torque.
Switch Torque: 4 (29.0/39.2) kg.m (lb.ft/N.m)
15. Plug
Tighten the plugs to the specified torque.
Plug Torque: 1.9 ± 0.4 (13.7 ± 2.9/18.6 ± 3.9) kg.m(lb.ft/N.m)
TRANSFER REAR CASE ASSEMBLY
Important Operations
2. Ball Bearing
Use the ball bearing installer and the adapter to install the ball bearing.Ball Bearing Installer : J-37223 Adapter J-37486
4. Clip - Install the clip to the drive gear groove.
7. Ball Bearing - Use the ball bearing installer to install the ball bearing. Ball Bearing Installer J-37223
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) Perform 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, 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) Clean and 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-37221
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)