Assembly (Part 2)

With All Wheel Drive




Synchronizer ring (4th), 4th gear, and bearing inner race
1. Install the synchronizer ring (4th), 4th gear, and bearing inner race with the SST.

NOTE: Press to 19,620 N (2,000 kg, 4,400 lb).




2. Measure the clearance between the 3rd gear and 2nd gear.

Clearance: 0.05 - 0.20 mm (0.002 - 0.008 in.)
Maximum: 0.25 mm (0.010 in.)




3. Measure the clearance between the 4th gear and bearing inner race.

Clearance: 0.165 - 0.365 mm (0.0064 - 0.0144 in.)
Maximum: 0.415 mm (0.0163 in.)

4. If not as specified, reassemble the primary shaft assembly.


Clutch Housing and Transaxle Case Components
1. Select the adjustment shim(s), referring to Bearing Preload Adjustment.
2. Assemble in the order shown in the image, referring to Assembly Note.




1. Clutch housing
2. Front cover
3. Oil seal
4. Oil seal (Front and center differential)
5. Plug
6. Pivot pin
7. Oil seal
8. Bearing outer race (Idler gear)
9. Bearing outer race
(Front and center differential)
10. Funnel
11. Bearing outer race
12. Oil seal
13. Bearing outer race
14. Reverse lever support
15. Lever set spring and steel ball
16. Baffle
17. Air breather
18. Breather dust boot and air breather
19. Bolt
20. Baffle
21. Baffle
22. Magnet
23. Plug
24. Ventilator covers
25. Dust cover
26. Transaxle case
27. Adjustment shim
28. Bearing outer race
29. Adjustment shim
30. Bearing outer race
31. Oil seal (Front and center differential)
32. Adjustment shim
33. Diaphragm spring
34. Bearing outer race
35. Adjustment shim
36. Diaphragm spring
37. Bearing outer race
38. Oil guide
39. Plug
40. Plug




Idler gear adjustment shim selection

NOTE: Measure at three locations and average the reading.

1. Place a straightedge on the transaxle case.
2. Measure the depth on the bearing outer race bore.




3. Set the idler gear assembly into the clutch housing.
4. Turn the idler gear assembly to seat the bearing.
5. Install the bearing outer race to the idler gear assembly.




6. Measure from the top of the bearing outer race to the clutch housing.

CAUTION: The number of shims used must not exceed two.




7. Select the shim as follows.
a. Subtract the bearing height (Step 6) from the depth of the bearing bore (Step 2).
b. Add 0.17 mm (0.0067 in.) to (a).
c. Add 0.22 mm (0.0087 in.) to (a).
d. Select the shim in the range between (b) and (c) from the image.




Bearing preload adjustment
Adjust the bearing preload of the primary shaft, secondary shaft, and front and center differential by selecting and installing the proper adjustment shim(s).




Primary and secondary shaft gear
1. Install the primary and secondary shaft bearing outer races into the transaxle case (shims removed).




2. As shown in the image, put the outer races into the SST.

NOTE: Turn the selector to eliminate the gap indicated by the arrow in the image.




3. Set the SST (selectors) in place.
4. Mount the primary and secondary shaft gear assemblies onto the SST (selectors).




5. Set the SST (collars) between the transaxle case and the clutch housing, install the SST (bolts) and tighten to the specified torque.

Tightening torque: 37 - 52 N-m (3.8 - 5.3 m-kg, 27 - 38 ft-lb)




6. To seat the bearings, mount the SST (bar) on parts (A) and (B) of the SST (selectors), and turn the selector so the gap is enlarged.
Move the bars by hand until the selector can no longer be turned, and then turn it in the reverse direction until the gap is eliminated.




7. Manually expand the SST (selector) for both shafts until the SST (selector) no longer turns.

NOTE: Make sure that each shaft turns smoothly.




8. Measure the gap of the SST (selector) for both gears.

NOTE:
- Measure the gap around the entire circumference of the SST (selector).
- The number of shims used must not exceed two.




9. Select an appropriate adjustment shim.
1. The shim for the primary shaft gear should be selected by referring to the image and selecting the shim which is nearest (on the thin side) to the value obtained by subtracting the thickness of the diaphragm spring, which goes between the shim and the race, from the measured value of the gap in the SST (selector).

Example: 0.94 mm (0.0370 in.)
0.94 mm (0.0370 in.) - 0.70 mm (0.0276 in.) = 0.24 mm (0.009 in.) [Diaphragm spring]
So the nearest shim (on thin side) to 0.24 mm (0.009 in.) is 0.20 mm (0.008 in.).

2. The shim for the secondary shaft gear should be selected by referring to the image and selecting the shim which is nearest (on the thick side) to the value obtained by subtracting the thickness of the diaphragm spring, which goes between the shim and the race, from the measured value of the gap in the SST (selector).

Example: 0.94 mm (0.0370 in.)
0.94 mm (0.0370 in.) - 0.70 mm (0.0276 in.) = 0.24 mm (0.009 in.) [Diaphragm spring]
So the nearest shim (on thick side) to 0.24 mm (0.009 in.) is 0.25 mm (0.010 in.).




10. Remove the SST (bolts and collars) and then remove the transaxle case, shaft gears and SST (selectors).
11. Remove the bearing outer races for both shafts from the transaxle case.




Front and center differential
1. Install the bearing outer race with the SST.




2. Install the front and center differential and bearing outer race.
3. Set the SST (selector) in place.




4. Set the SST (collars) between the transaxle case and the clutch housing, and install the SST (bolts), and tighten to the specified torque.

Tightening torque: 37 - 52 N-m (3.8 - 5.3 m-kg, 27 - 38 ft-lb)

5. Seat the bearings by turning the SST (selector) with the SST (bar) until the gap is enlarged.




6. Insert the SST.




7. Expand the SST (selector) until the proper preload specification is obtained.

Preload: 2.9 - 3.9 N-m (30 - 40 cm-kg, 26 - 35 in-lb)

NOTE: Measure the gap around the entire circumference of the selector.




8. Measure the gap in the SST (selector).

NOTE: The number of shims used must not exceed three.




9. Select an appropriate adjustment shim to be used for the differential. It should be selected by referring to the image and selecting the shim which is nearest (on thick side) to the largest measured value of the gap in the SST (selector).

Example: 0.54 mm (0.021 in.)
So the nearest shim (on thick side) to 0.54 mm (0.021 in.) is 0.6 mm (0.014 in.).

10. Remove the SST (bolts and collars) and then remove transaxle case.
11. Remove the SST (selector), bearing outer race and front and center differential.




Bearing preload
Verify that the shaft gears and differential bearing preload is correct.

NOTE:
- Verify that the correct adjustment shims were selected.
- If the bearing preload is not within specification, readjust.

1. Set the primary shaft gear and the differential into the clutch housing.




2. Install the selected shim and bearing outer race for the front and center differentials with the SST.




3. Install the selected shim, diaphragm spring and bearing outer race for the primary shaft.
4. Install the transaxle case, and tighten to the specified torque.

Tightening torque: 37 - 52 N-m (3.8 - 5.3 m-kg, 27 - 38 ft-lb)




5. Install the SST through the driveshaft opening.
6. Hook a spring scale to the attachment and measure the preload.

Preload: 2.9 - 3.9 N-m (30 - 40 cm-kg, 26 - 35 in-lb)




7. Remove the SST.
8. With the transaxle facing in the direction shown in the image, install the SST to the primary shaft gear.
9. Measure the preload.

Preload: 0.1 - 0.25 N-m (1.0 - 2.5 cm-kg, 0.87 - 2.18 in-lb)




10. Remove the SST, transaxle case, primary shaft gear and differential.
11. Install the secondary shaft gear and transaxle case, then tighten to the specified torque.

Tightening torque: 37 - 52 N-m (3.8 - 5.3 m-kg, 27 - 38 ft-lb)




12. Measure the secondary shaft preload with the SST.

Preload: 0.29 - 0.42 N-m (3.0 - 4.3 cm-kg, 2.6 - 3.7 in-lb)




Assembly note
Oil seal (Front and center differential)

CAUTION: Apply transaxle oil to the outer circumference of the oil seal.

1. Install the new oil seal with the SST.




Oil seal (Center differential lock shift rod)

CAUTION: Apply transaxle oil to the oil seal lip.

1. Install the new oil seal with a suitable pipe.




Bearing outer race (Idler gear)
1. Install the bearing outer race with the SST.




Bearing outer race (Front and center differential)
1. Install the bearing outer race with the SST.




Diaphragm spring
1. Install the diaphragm spring as shown in the image.

5th/Reverse Gear and Housing Parts
1. Assemble in the order shown in the image, referring to Assembly Note.




1. Clutch hub
2. Synchronizer keys
3. Clutch hub sleeve
4. Synchronizer key springs
5. Speedometer sleeve
6. Oil seal (Speedometer driven gear assembly)
7. Speedometer driven gear
8. O-ring
9. Clutch housing assembly
10. Transfer carrier assembly
11. Dynamic damper
12. Shift rod (1st/2nd)
13. Shift fork (1st/2nd)
14. Shift rod end
15. Shift rod (3rd/4th)
16. Shift fork (3rd/4th)
17. Center differential lock shift fork
18. Idler gear assembly
19. Front and center differential assembly
20. Shift gate
21. Shift fork assembly (1st/2nd)
22. Shift fork assembly (3rd/4th)
23. Secondary shaft assembly
24. Primary shaft assembly
25. Shift rod
26. Shift rod end
27. Shift rod assembly
28. Bolt
29. Bolt
30. Reverse idler gear shaft
31. Reverse idler gear support
32. Reverse idler gear
33. Reverse idler gear shaft assembly
34. Interlock pin
35. Transaxle case assembly
36. Bolt
37. Steel balls and springs
38. Top cover assembly
39. Back-up light switch
40. Neutral switch
41. Interlock pins
42. Interlock plate
43. Gear sleeve
44. Secondary 5th gear
45. Primary 5th gear
46. Synchronizer ring
47. Clutch hub assembly
48. Shift fork
49. Secondary reverse synchronizer gear
50. Synchronizer ring
51. Primary reverse synchronizer gear
52. Locknut
53. Spacer
54. Locknut
55. Rear cover
56. Speedometer driven gear assembly
57. Center differential lock motor
58. Center differential lock switch
59. Differential lock set bolt
60. Clutch release fork
61. Clutch release bearing




Assembly note
Oil seal (Speedometer driven gear assembly)
1. Install the new oil seal with a suitable pipe.

Pipe diameter: 16 mm (0.629 in.)




Speedometer driven gear
1. Install the new roll pin as shown in the image.




Primary shaft assembly, secondary shaft assembly, front and center differential assembly, Idler gear assembly

CAUTION: Do not damage the oil seal.

WARNING: Do not cut your hands on the baffle when installing.




1. Lean the clutch housing.
2. Install the front and center differential assembly, idler gear, and center differential shift fork assembly.
3. Hold up the front and center differential assembly and idler gear assembly so that primary shaft and secondary shaft can be removed.




4. Align the shift forks (1st/2nd and 3rd/4th) as shown.
5. Install the primary shaft assembly, secondary shaft assembly, and shift fork assembly.
6. Verify that the gears are properly engaged.




Reverse idler gear shaft assembly

CAUTION: Verify that the gears are properly engaged.

1. Align the lock bolt hole and mark of the clutch housing.




Interlock pin
1. Install the interlock pins as shown in the image.




Top cover assembly
1. Install the steel balls and the springs.




2. Install the top cover.
3. Install the boot with the air bleed downward as shown in the image.




Transaxle case assembly
1. Apply a thin coat of sealant to the contact surfaces of the clutch housing and transaxle case.
2. Install and tighten the transaxle case installation bolts to the specified torque.

Tightening torque: 37 - 52 N-m (3.8 - 5.3 m-kg, 27 - 38 ft-lb)




3. Install the bolt.




Locknut
1. Shift to 1st gear.
2. Lock the primary shaft with the SST.
3. Tighten new locknuts on the primary and secondary shafts.

Tightening torque: 128 - 206 N-m (13.0 - 21 m-kg, 94 - 152 ft-lb)

4. Stake the locknuts to the groove.




Primary 5th gear

NOTE: After installation, move the shift rod to verify that the gear change operation is smooth.

1. Shift to neutral and install the roll pin.




Rear Cover

NOTE: Clean the contact surfaces before applying sealant.

1. Apply sealant to the transaxle case and rear cover.
2. Install the rear cover.

Tightening torque: 7.8 - 11 N-m (0.8 - 1.1 m - kg, 5.8-8.0 ft-lb)




Center Differential Lock motor
1. Install the center differential lock motor.

Tightening torque: 19 - 25 N-m (1.9 - 2.6 m-kg, 14 - 19 ft-lb)




2. Turn the rod 180° counterclockwise with a screwdriver, and install the plug.
3. Install the bolts.

Tightening torque: 9 - 14 N-m (90 - 140 cm-kg, 78 - 122 ft-lb)

4. Install the differential lock switch.

Tightening torque: 20 - 29 N-m (2 - 3 m-kg, 14 - 22 ft-lb)