Step 5
ASSEMBLY-STEP 5
Assemble in the sequence shown in the image.
Transfer Carrier
1. Coat both surfaces with sealant.
2. Install the transfer carrier assembly.
Tightening torque: 25-30 N.m (2.5-3.1 m-kg, 18.1-22.4 ft-lb)
NOTE: Before coating with sealant, clean the contact surfaces.
Front Differential Assembly
1. Assemble the center differential lock shift fork assembly to the center differential assembly, and in stall the center differential assembly into the clutch housing.
2. Install the set bolt.
Shaft Gear and Shift Fork Assembly
Install the primary shaft gear, secondary shaft gear, and shift fork assembly according to the following procedures:
1. Set the control end in place.
2. Install the shift fork assembly on the secondary shaft gear assembly.
3. Unite the primary shaft gear, secondary shaft gear and shift fork assembly. Install the control rod into the control end as the unit is lowered into place.
NOTE: Keep the assembly nearly vertical while installing.
Idle Gear
Install the idle gear.
Control End
Tap the spring pin in with a pin punch and hammer.
Reverse Lever Support and Shift Gate
1. Install the reverse lever support and shift gate.
2. Install the shift rod (5th/reverse)
Tightening torque: 11.8-15.7 N.m (1.2-1.6 m-kg, 8.7-11.6 ft-lb)
3. Assemble the shift gate and install the shift rod then align the control lever and shift gate.
4. Tighten the set bolt.
Tightening torque: 11.8-15.7 N.m (1.2-1.6 m-kg, 8.7-11.6 ft-lb)
Reverse Idle Shaft
Set the reverse idle shaft in the direction shown.
Transaxle Case
1. Install the magnet.
2. Coat both surfaces with sealant.
NOTE: Before coating with sealant, clean the contact surfaces.
3. Install the transaxle case.
4. Install the detent ball, spring and bolt (A), set bolts (B), (C) and case bolt (D).
NOTE: Coat the threads of (A) (B) (C) bolts with sealant before installing.
Tightening torque:
(A) : 14.7-20.6 N.m (1.5-2.1 m-kg, 10.8-15.2 ft-lb)
(B) : 8.8-13.7 N.m (90-140 cm-kg, 73-122 in-lb)
(C) : 18.6-25.5 N.m (1.9-2.6 m-kg, 13.7-18.8 ft-lb)
(D) : 37.3-52.0 N.m (3.8-5.3 m-kg, 27.5-38.3 ft-lb)
Side Cover
1. Lift the idle gear slightly.
2. Install the "O" ring.
3. Coat the side cover and clutch housing with sealant.
NOTE: Before coating with sealant, clean the contact surfaces.
4. Install the side cover.
Tightening torque:
A. 37.3-52.0 N.m (3.8-5.3 m-kg, 27.5-38.3 ft-lb)
B. 18.6-25.5 N.m (1.9-2.6 m-kg, 13.7-18.8 ft-lb)
5th Gear
1. Install the SST to hold the side gear.
2. Install the secondary 5th gear.
3. Install the gear sleeve, the 5th gear and synchronizer ring.
4. Install the shift fork together with clutch hub assembly.
5. Install the synchronizer ring.
6. Install the gear sleeve and reverse synchronizer gears.
7. Shift the lever into 1st gear.
8. Lock the primary shaft with the SST.
9. Use new lock nuts and tighten it to the specified torque.
Tightening torque: 127-206 N.m (13-21 m-kg, 94-152 ft-lb)
10. Stake the lock nuts to the groove.
11. Shift to neutral and install the spring pin.
NOTE: After installation, move the shift rod to check to be sure that the gear change operation is smooth.
Rear Cover
1. Coat the transaxle case and rear cover with sealant.
NOTE: Before coating with sealant, clean the contact surfaces.
2. Install the rear cover.
Tightening torque: 7.8-11 N.m (0.8-1.1 m-kg, 5.8-8.3 ft-lb)
Center Differential Lock Assembly
1. Position the center differential lock shift rod as shown in the image.
2. Install the center differential lock assembly.
Tightening torque: 18.6-25.5 N.m (1.9-2.6 m-kg, 13.7-18.8 ft-lb)
3. Turn the rod 90°C counterclockwise with a flat-tipped screwdriver.
4. Install the bolts.
Tightening torque: 8.8-13.7 N.m (0.9-1.4 m-kg, 6.5-10.1 ft-lb)
5. Install the differential lock switch.
Tightening torque: 19.6-29.4 N.m (2-3 m-kg, 14.5-21.7 ft-lb)
Switch
Install the neutral switch and backup lamp switch.
Tightening torque: 19.6-29.4 N.m (2-3 m-kg, 14.5-21.7 ft-lb)