Unit
Disassembly & Reassembly (Part 1):
Disassembly & Reassembly (Part 2):
Disassembly & Reassembly (Part 3):
Disassembly & Reassembly (Part 4):
Disassembly & Reassembly (Part 5):
Disassembly & Reassembly (Part 6):
DISASSEMBLY SERVICE POINTS
H-L SHIFT RAIL REMOVAL
1. Shift the 2AWD shift rail to the 4WD position.
NOTE: If the 2-4WD shift rail in left in the 2WD position, the interlock is actuated, preventing removal of the H-L shift rail.
2. Remove the H-L shift rail.
H-L SHIFT RAIL / CHAIN COVER REMOVAL
1. Use a poppet spring to fix the H-L shift rail at the High side.
2. Shift the 2AWD shift rail to the 4WD position.
NOTE: If the 24WD shift rail is left in the 2WD position, the interlock will actuate, preventing removal of the chain cover.
3. Remove the chain cover, and then remove the H-L shift rail.
REAR OUTPUT SHAFT ASSEMBLY / CHAIN / FRONT OUTPUT SHAFT ASSEMBLY REMOVAL
Remove the front output shaft, rear output shaft and chain together.
COUNTER GEAR SHAFT REMOVAL
The counter gear shaft should be pulled out forward the trans- mission case side.
SPRING PIN REMOVAL
Use a pin punch or similar tool to tap out the spring pin.
Caution: Remove the pin with care, as there is a danger that the spring may fly out.
2-4 SYNCHRONIZER ASSEMBLY / CHAIN / FRONT OUTPUT SHAFT ASSEMBLY REMOVAL
Remove the 2A synchronizer assembly, chain and front output shaft from the transmission as a unit.
INSPECTION
DETECTION SWITCH INSPECTION
Inspect the continuity between the connector terminal and the switch body.
REASSEMBLY SERVICE POINTS
OIL SEAL (FRONT OUTPUT SHAFT) INSTALLATION
Apply transmission oil to the lip of the oil seal and pressure insert it.
OIL SEAL (INPUT GEAR) INSTALLATION
Apply transmission oil to the lip of the oil seal and pressure insert it.
OIL SEAL INSTALLATION
Use a socket wrench or similar tool to install the oil seal.
SNAP RING INSTALLATION
Select the thickest snap ring that will fit into the groove and install it.
Standard value: 0-0.06 mm (0-.0024 in.)
2-4WD SHIFT RAIL / 2-4WD SHIFT LUG / SPRING RETAINER / SPRING / SPRING PIN INSTALLATION
1. Install the spring retainer and spring to the shift rail, and set it to the shift lug inside the transfer case.
2. Press the shift rail and align the shift lug and the spring pin hole of the shift rail, while being careful of the direction of the shift rail.
3. While pressing the rail, tap in the spring pin so that the slit of the spring pin is facing the shaft centre of the shift rail.
THRUST WASHER INSTALLATION
Install the thrust washer so that the tab fits into the groove of the transfer case.
COUNTER GEAR SHAFT INSTALLATION
Insert the counter gear shaft from the transmission case side, being careful of the position of the lock plate groove.
REAR OUTPUT SHAFT ASSEMBLY / CHAIN / FRONT OUTPUT SHAFT ASSEMBLY INSTALLATION
1. Engage the chain precisely with the sprockets of the rear output shaft and the front output shaft.
2. Install the 2-4WD shift fork on the 2-4WD clutch sleeve. While passing them along the 2-4WD shift rail, install the rear and front output shaft and chain.
BEARING RETAINER INSTALLATION
A precoated bolt is used for the bearing retainer, so if it is being re-used, apply specified sealant to the thread section of the bearing retainer, and then install the bearing retainer.
Specified adhesive: 3M STUD Locking No.4170 or equivalent.
SNAP RING INSTALLATION
When installing the snap ring, select the one with the maximum thickness that can fit in the groove.
Standard value: 0-0.08 mm (0-.0031 in.)
2-4WD SYNCHRONIZER ASSEMBLY / CHAIN / FRONT OUTPUT SHAFT ASSEMBLY INSTALLATION
1. Make a mark with white paint, etc., in the grooves of the 2-4WD synchronizer (3 places).
2. Make a mark with white paint, etc., on the spline projections of the 2-4WD synchronizer sleeve (3 places).
3. Link the chain tightly onto the 2-4WD synchronizer and the front output shaft sprockets.
4. Install both sprockets to the transfer case at the same time, while keeping them at the maximum distance apart.
CHAIN COVER INSTALLATION
Install the chain cover so that the end of the oil guide may enter the hole shown in the illustration.
CHAIN COVER / INTERLOCK PLUNGER INSTALLATION
1. Insert the interlock plunger in a position so that it does not interfere with the 2-4WD shift rail.
2. Apply specified sealant to the chain cover, and then install the chain cover.
Specified sealant: 3M ATD Part No.8660 or equivalent.
Caution: Apply the proper amount of sealant evenly.
H-L SHIFT RAIL INSTALLATION
1. Shift the 2-4WD shift rail to the 4WD position.
2. Insert the H-L shift rail from the case and pass the rail through the shift fork.
H-L SHIFT RAIL / SPRING PIN FOR H-L SHIFT FORK INSTALLATION
1. Insert the H-L shift rail from the H-L shift rail hole, being careful of the direction of the shift rail.
2. Align the spring pin holes on the shift rail and the shift fork, and tap in the spring pin so that the slit of the spring pin is facing the shaft centre of the shift rail.
COVER / WAVE SPRING (SPACER) INSTALLATION
1. Measure the amount of protrusion of the front output shaft rear bearing "A" and the amount of inset of the cover "B". If the value of "B" exceeds the value of "A" by 2 mm (.08 in.), add a spacer in between the wave spring and the cover. If the difference is less than 2 mm (.08 in.), the wave spring by itself is okay.
2. Apply specified sealant to the cover and the thread section of the mounting bolt, and then install the cover.
Specified sealant, adhesive 3M ATD Part No.8660 or equivalent for Cover.
3M STUD Locking No.4170 or equivalent for Bolt.
Caution: Apply the proper amount of sealant evenly.
COVER GASKET I COVER INSTALLATION
1. Measure the projection (A) of the rear bearing from the end of the front output shaft and the depth (B) of indentation in the cover.
If the clearance (a difference between A and B) exceeds 2 mm (.08 in.) insert a spacer between the cover and the wave spring. If the clearance is 2 mm (.08 in.) or less, use the wave spring alone.
2. Apply specified sealant to both sides of the cover gasket
Specified sealant: 3M ATD Part No.8660 or equivalent.
3. Install the cover.
4. Apply the specified adhesive to the threaded part of the cover installation bolt.
5. Tighten the cover installation bolt at the specified torque.
SPACER INSTALLATION
Measure the clearance "B" between the chain cover and the snap ring of the ball bearing, and select the spacer according to the thickness gained by adding the following standard value to clearance "B". Then, assemble the spacer.
Standard value: 0.02-0.1 mm (.0008-.0039 in.)
OIL SEAL INSTALLATION
OIL SEAL INSTALLATION
Apply transmission oil to the lip of the oil seal before press-fitting.
SPACER INSTALLATION
Measure the amount of protrusion of the rear output shaft bearing "A" and the amount of inset of the two stages of the cover "B". Calculate the value "C" by subtracting "B" from "A", and then select a snap ring which adjusts the difference between the value of "C" and the thickness of the spacer to the standard value below.
SPACER / REAR COVER GASKET / REAR
COVER INSTALLATION
1. Measure the amount of protrusion of the rear output shaft rear bearing "A" and the amount of inset in the cover "B". Select a spacer which adjusts the end play to the standard value.
Standard value: 0-0.1 mm (0-.004 in.)
2. Apply sealant to both sides of the rear cover gasket.
Specified sealant: 3M ATD Part No.8660 or equivalent.
REAR COVER INSTALLATION
Apply specified sealant to the rear cover, and then install the cover.
Specified sealant: 3M ATD Part No.8660 or equivalent.
Caution: Apply the proper amount of sealant evenly.
SPEEDOMETER GEAR INSTALLATION
Match the mating marks to the number of teeth.
SEALANT APPLICATION TO POPPET PLUG
Apply specified sealant to the poppet plug, and then install the poppet plug.
Specified sealant: 3M ATD Part No.8660 or equivalent.
SEALANT APPLICATION TO PLUG
A pre-coated plug is used, so if it is being re-used, apply specified sealant to the thread section, and then install.
Specified sealant: 3M ATD Part No.8660 or equivalent.
DETECTION SWITCH INSTALLATION
Be careful not to make a mistake when installing.
A. Ball built-in, brown connector
B. Ball built-in, black connector
C. Ball separate, brown connector
D. Ball separate, black connector
E. Ball separate, white connector
SPRING PIN INSTALLATION