Transmission

TRANSMISSION CASE AND TRANSFER CASE





MAJOR COMPONENT (MUA, 4X4)

DISASSEMBLY
1. Clean the exterior of the unit with solvent.
2. Remove the drain plug from the transmission case and transfer case and drain the lubricant.





3. Remove the clutch release bearing (1) from the transmission case.





4. Remove the snap pin. Remove the shift fork pin and shift fork (2) from the fulcrum bridge (3).





5. Remove the fulcrum bridge bolts.
- Remove the fulcrum bridge (3) from the transmission case. Remove the front cover (4) and gasket from the transmission case.





6. Remove counter front bearing snap ring (5) and top gear bearing snap ring (6). Use a pair of snap ring pliers to remove the snap ring.
7. Remove the speedometer sensor (7). Remove the plate (7). Remove the driven gear bushing and driven gear (7).

NOTE: Apply a reference mark to the driven gear bushing before removal.





8. Remove front companion flange (8) and rear companion flange (9) using the flange holder J-8614-11 to remove the end nut.
9. Disconnect breather hose from transmission and remove gear control box assembly (10).
10. Remove 2WD-4WD actuator assembly (11) by performing the following steps:





1. Disconnect the actuator breather hose from 2WD-4WD actuator assembly (11).
2. Remove the 2WD-4WD actuator assembly bolts.





3. Pull the 2WD-4WD actuator assembly with 2WD-4WD shift rod.





4. Offset the actuator assembly.





5. Remove the actuator assembly.

NOTE: Before removing the transmission and transfer assembly from vehicle, change the transfer mode to 2WD using the 4WD push button switch on dash panel.

11. Remove the transfer rear case assembly (12) from the transfer case (28).
12. Regarding detent, shift arm, and interlock pin (13) disassembly.
13. Use a pair of snap ring pliers to remove the bearing snap ring (14).





14. Use a bearing remover J-37217 and puller J-3748 to remove the ball bearing (15).





15. Install the front companion flange temporarily. Use the flange holder J-8614-11 and lock nut wrench J-37219 to remove the lock nut (16). Remove the front companion flange.





16. Remove high-low clutch sleeve (17). Use the universal puller to remove the high-low clutch hub (17) and transfer input gear (18).





17. Remove needle bearing (19), bearing collar (20), ball (21), and plate (22).

18. Use a pair of snap ring pliers to remove the bearing snap ring (23).
19. Use a plastic hammer to tap the front output gear assembly (24) free.
20. Remove bearing snap ring (25) by using a pair of snap ring pliers.





21. Remove the counter gear assembly (26) from the transfer case (28).
22. Remove 1-2 and 3-4 indicator switch, pin and ball (27).
23. Remove the transfer case assembly (28) from the transmission case.
24. Pull out intermediate plate with gear assembly (29) from transmission case.

REASSEMBLY
1. Apply recommended liquid gasket (LOCTITE 17430) or its equivalent to the transmission case (30), intermediate plate (29) and transfer case (28) fitting surfaces.
2. Install the intermediate plate with gear assembly (29) to the transmission case (30). 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.
3. Install the transfer case assembly (28) to the intermediate plate with gear assembly. Tighten the eight transmission-transfer case bolts to the specified torque.

Torque: 37 Nm (27 ft. lbs.)

Refer to Transfer Case; Service and Repair; Unit Overhaul for oil seal replacement.
4. Install 1-2 and 3-4 indicator switch, pin and ball (27).
5. Install the counter gear assembly (26) to the transfer case (28).
6. Use a pair of snap ring pliers to install the snap ring (25) to the transfer case (28).

NOTE: The snap ring must be fully inserted into the transfer case snap ring groove.

7. Install front output gear assembly (24).
8. Use a pair of snap ring pliers to install the snap ring (23) to the transfer case (28).

NOTE: The snap ring must be fully inserted into the transfer case snap ring groove.

9. Install plate (35), ball (34), bearing collar (33), needle bearing (32), and transfer input gear (31).





10. Install High-low clutch hub and sleeve (17). The clutch hub face (with the heavy boss) must be facing the transfer input gear side.





11. Install the front companion flange temporarily.
- Use the flange holder J-8614-11 and lock nut wrench J-37219 to install the lock nut (16).

Torque: 137 Nm (101 Ft. lbs.)

12. Use the punch to stake the lock nut at one spot.





13. Use a suitable drift and hammer to install the ball bearing (15).
14. Use a pair of snap ring pliers to install the bearing snap ring (14).
15. Regarding detent, shift arm, and interlock pin (13) assembly.





16. Apply recommended liquid gasket (LOCTITE 17430) or its equivalent to the transfer rear case fitting faces.





17. Perform the following steps before fitting the transfer rear case (12):
1. Shift the High-Low shift to the 4H side.
2. The cut-away portion of select rod head should align with the rear case hole's stopper.
18. Tighten the eleven transfer rear case bolts to the specified torque.

Torque: 37 Nm (27 ft. lbs.)

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.

19. Install 2WD-4WD actuator assembly (11) by performing the following steps.
1. Shift the 2WD-4WD shift rod to the 4WD side.





2. Join the rod grooves of 2WD-4WD actuator assembly and shift rod.





3. Push the 2WD-4WD actuator assembly with 2WD-4WD shift rod till the shift rod reaches the 2WD position.
4. Tighten the 2WD-4WD actuator bolts to the specified torque.

Torque: 19 Nm (14 ft. lbs.)

5. Connect the actuator breather hose to actuator.





20. Install a new packing and gear control box assembly (10). Install the harness clips and brackets and then tighten four new gear control box bolts to the specified torque.

Torque: 20 Nm (14 ft. lbs.)





21. Install the rear and front companion flange (9) (8). Install the O-ring (9). Use the flange holder J-8614-11 to tighten the flange nuts (9) (8) to the transfer case. Tighten new transfer flange nuts (9) (8) to the specified torque.

Rear Companion Flange
Torque: 167 Nm (123 ft. lbs.)
Front Companion Flange
Torque: 137 Nm (101 Ft. lbs.)








22. Use the punch J-39209 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.





23. Install the O-ring (4) to the speedometer driven gear bushing (3). Install the driven gear to the speedometer driven gear bushing (3). Install the speedometer driven gear assembly (7) to the transfer rear cover.
24. Install the plate to the transfer rear cover.

Torque: 15 Nm (11 ft. lbs.)

25. Install the speedometer sensor.

Torque: 27 Nm (20 ft. lbs.)

26. Install top gear bearing snap ring (6) and counterfront bearing snap ring (5).
Use a pair of snap ring pliers to install the snap rings As to the mainshaft and countershaft.
The snap rings must be fully inserted into the bearing snap ring groove.
27. Install a new packing and front cover (with oil seal) (4) 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 Nm (18 ft. lbs.)





28. Install the fulcrum bridge (3) to the transmission case. Tighten three fulcrum bridge bolts to the specified torque.

Torque: 38 Nm (28 ft. lbs.)





29. Apply grease to the pin hole inner circumferences and thrust surfaces. Attach the shift fork (2) to the fulcrum bridge (3) by inserting the shift fork pin from the bottom side of the fulcrum bridge. Install the washer and snap pin.





30. Apply grease to the areas shown in the figure.





Install the release bearing (1) to the shift fork (2) in the proper direction.

NOTE: Ensure release bearing is properly positioned during installation, as shown in the figure.