Transmission Case and Transfer Case
MAJOR COMPONENT
DISASSEMBLY
Preparation:
- Clean the exterior of the unit with solvent.
- Remove the drain plug from the transmission case and transfer case and drain the lubricant.
1. Clutch release bearing
- Remove the clutch release bearing from the transmission case .
2. Shift fork
- Remove the snap pin.
- Remove the shift fork pin and shift fork from the fulcrum bridge.
3. Fulcrum bridge
- Remove the fulcrum bridge bolts.
- Remove the fulcrum bridge from the transmission case.
4. Front cover (with oil seal)
- Remove the front cover from the transmission case.
5. Snap ring; counter front bearing
6. Snap ring; top gear bearing
- Use a pair of snap ring pliers to remove the snap ring.
7. Speedometer sensor and speedometer driven gear.
- Remove the speedometer sensor.
- Remove the plate.
- Remove the driven gear bushing and driven gear.
NOTE: Apply a reference mark to the driven gear bushing before removal.
8. Front companion flange
9. Rear companion flange
- Use the flange holder to remove the end nut.
Flange holder : J-37221
- Remove the front and rear companion flange.
10. Gear control box assembly
11. Transfer rear case assembly
- Remove the transfer rear case assembly from the transfer case.
12. 1-2 and 3-4 indicator switch, pin and ball
13. Detent, shift arm, and interlock pin (Transfer case assembly)
14. Transfer case assembly
- Remove the transfer case together with intermediate plate with gear assembly from the transmission case.
15. Intermediate plate with gear assembly
16. Transmission case
REASSEMBLY
To reassemble, follow the disassembly steps in the reverse order, noting the following points:
16. Transmission case
15. Intermediate plate with gear assembly
14. Transfer case assembly
- Apply recommended liquid gasket (LOCTITE FMD 127) or its equivalent to the transmission case, intermediate plate and transfer case fitting surfaces.
- Install the transfer case together with intermediate plate with gear assembly to the transmission case.
- Pull out the top gear shaft until the ball bearing snap ring groove protrudes from the transmission case front cover fitting face. Avoid subjecting the mainshaft to sudden shock or stress.
- Tighten the seven transmission-transfer case bolts to the specified torque.
Torque : 37 (27) N.m (lb.ft)
13. Detent, shift arm, and interlock pin (Transfer case assembly)
12. 1-2 and 3-4 indicator switch, pin and ball
11. Transfer rear case assembly
- Apply recommended liquid gasket (LOCTITE FMD 127) or its equivalent to the transfer rear case fitting faces.
- Perform the following steps before fitting the transfer rear case.
1. Shift the High-Low shift 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.
3. The cut-away portion of select rod head (B) should align with that of the rear case hole's stopper (C).
- Tighten the eleven transfer rear case bolts to the specified torque.
Torque : 37 (27) N.m (lb.ft)
NOTE:
Notes when tightening the bolt:
- After cleaning the bolt hole, dry it thoroughly with air.
- After cleaning the screw face of a removed bolt or new one, dry it thoroughly. Apply recommended liquid gasket (LOCTITE 242) or its equivalent before tightening it.
10. Gear control box assembly
- Install a new gasket.
- Install the harness clip and then tighten four new gear control box bolts to the specified torque.
Torque : 20 (14) N.m (lb.ft)
9. Rear companion flange
8. Front companion flange
- Install the rear and front companion flange.
- Install the O-ring.
- Use the flange holder to tighten the flange nuts to the transfer case.
Flange holder : J-37221
- Tighten new transfer flange nuts to the specified torque.
Torque:
Rear companion flange : 167 (123) N.m (lb.ft)
Front companion flange : 137 (101) N.m (lb.ft)
- Use the punch to stake the rear companion flange nut at two spots.
Punch : J-39209
- Stake the front companion flange nut at one spot.
NOTE: Be sure to confirm that there is no crack at the staked portion of the flange nut after staking.
7. Speedometer driven gear and Speedometer sensor
- Install the O-ring to the speedometer driven gear bushing.
- Install the driven gear to the speedometer driven gear bushing.
- Install the speedometer driven gear assembly to the transfer rear cover.
- Install the plate to the transfer rear cover.
Torque : 15 (11) N.m (lb.ft)
- Install the speedometer sensor.
Torque : 27 (20) N.m (lb.ft)
6. Snap ring; top gear bearing
5. Snap ring; counter front bearing
- Use a pair of snap ring pliers to install the snap rings to the mainshaft.
- The snap rings must be fully inserted into the bearing snap ring groove.
4. Front cover (with oil seal)
Oil seal replacement
- Remove the oil seal from the front cover.
- Apply engine oil to the oil seal outer circumference.
- Apply recommended grease to the oil seal lip.
- Use the oil seal installer to install the rear seal to the front cover.
Oil seal installer : J-29769
- Install a new packing and front cover to the transmission case.
NOTE: Take care not to damage the oil seal.
Notes when tightening the bolt:
- After cleaning the bolt hole, dry it thoroughly with air.
- After cleaning the screw face of a removed bolt or new one, dry it thoroughly. Apply recommended liquid gasket (LOCTITE 242) or its equivalent before tightening it.
Tighten six new front cover bolts to the specified torque.
Torque : 25 (18) N.m (lb.ft)
3. Fulcrum bridge
- Install the fulcrum bridge to the transmission case.
- Tighten three fulcrum bridge bolts to the specified torque.
Torque : 38 (28) N.m (lb.ft)
2. Shift fork
- Apply grease to the pin hole inner circumferences and thrust surfaces.
- Attach the shift fork to the fulcrum bridge by inserting the shift fork pin from the bottom side of the fulcrum bridge.
- Install the washer and snap pin.
1. Release bearing
- Apply grease to the areas shown.
- Install the release bearing to the shift fork in the proper direction.
NOTE: Ensure release bearing is properly positioned during installation, as shown.