Installation

INSTALLATION

NOTE: The output shaft shim should be 0.3 mm (0.012 in.). If a 0.3 mm (0.012 in.) shim is not available, use a 0.2 mm (0.008 in.) 0.4 mm (0.016 in.) or 0.5 mm (.020 in.) shim.





CAUTION: Verify that the geartrain end-play shim is properly installed over the output shaft and against the park gear.

NOTE: The closed side of the bearing must be installed toward the parking lock gear. If the bearing is installed in the other direction, the transmission gearcase will need to be removed in order to remove the bearing.

1. Using Bearing Installer 9287 (1), install the output shaft bearing (2) into the transmission housing (3). The closed side of the plastic cage must point towards the parking lock gear.




2. Install the retaining ring (1). Ensure that the retaining ring is seated correctly in the groove.
3. Check that there is no play between the bearing and the retaining ring using feeler gauge.
4. There must be no play between the retaining ring and the bearing. If the ring cannot be installed, a thinner ring must be used. If there is play between the ring and the bearing, a thicker ring must be installed. Retaining rings are available in thicknesses of 2.0 mm (0.079 in.), 2.1 mm (0.083 in.), and 2.2 mm (0.087 in.).




5. Install the output shaft washer onto the output shaft.
6. Install a new transmission rear seal into the transmission case with Seal Installer 8902A (1).
7. For 4WD transmissions:
a. Install the output shaft extension onto the output shaft.
b. Install the nut to hold the output shaft extension to the output shaft. Torque the bolt to 200 Nm (148 ft.lbs.).
c. Install the transfer case adapter housing onto the transmission case.
d. Install the bolts to hold the transfer case adapter housing onto the transmission case. Torque the bolt to 20 Nm (177 in.lbs.).
e. Install the transfer case.
8. For 2WD transmissions, install the propeller shaft flange onto the output shaft and install an new flange nut. Tighten the flange nut, with a 30 mm 12 point socket, to 200 Nm (148 ft.lbs.).





NOTE: The Staking Tool - 9078 has two possible locations for the beveled staking pin. The pin must be installed in the hole labeled "Transmission" for this operation. This hole is located directly across from the spring loaded alignment pin.

9. Place the Staking Tool 9078 and Driver Handle C-4171 onto the output shaft.
10. Rotate the Staking Tool 9078 (2) until the alignment pin (3) engages the output shaft notch (4).




11. Press downward on the staking tool until the staking pin contacts the output shaft nut flange.
12. Strike the Driver handle C-4171 with a suitable hammer until the output shaft nut is securely staked to the output shaft.
13. For 2WD transmissions, install the propeller shaft.