Assembly
TRANSFER CASE / Assembly1. Assemble front case.
a. Install main gear assembly by tapping lightly.
b. Apply sealant to the mating surface and bolts of front case cover, then attach it to the front case.
Use genuine anaerobic liquid gasket, Three Bond TB1215, Loctite Part No. 51813 or equivalent.
These ten bolts should be coated with sealant.
Bolts A: 20 - 24 Nm (2.0 - 2.4 kg.m, 14 - 17 ft. lbs.)
Bolts B: 24 - 28 Nm (2.4 - 2.9 kg.m, 17 - 21 ft. lbs.)
c. Apply ATF to needle bearing and install it into main gear.
d. Install counter gear assembly by tapping lightly.
e. Install cross shaft and inner shift lever.
When replacing cross shaft, outer shift lever or outer shift lever lock pin, replace them as a set.
f. Apply sealant to plug and install it into front case.
Use genuine anaerobic liquid gasket, Three Bond TB1215, Loctite Part No. 51813 or equivalent.
g. Insert interlock plunger into front case.
h. Install L & H shift rod and fork assembly with coupling sleeve.
i. Install 2-4 shift rod.
j. Install transfer neutral position switch, check balls, check springs and plugs.
Apply sealant to switches and plugs.
Use genuine anaerobic liquid gasket, Three Bond TB1215, Loctite Part No. 51813 or equivalent.
2. Select counter gear rear bearing shim.
a. Seat counter gear assembly.
b. Place J34291-1 (bridge), J34291-2 (legs) and J34291-5 (gauging cylinder) on machined surface of center case, allowing gauging cylinder to rest on top outer portion of counter gear rear bearing. Lock gauging cylinder in place.
c. Insert J34291-20 (gauging plunger) into J34291-5 (gauging cylinder).
d. Place bridge, legs, gauging cylinder and gauging plunger onto machined surface of front case assembly, allowing gauging plunger to drop until it contacts counter gear rear bearing mating surface.
e. Lock gauging plunger in place and use feeler gauge to measure end play between gauging cylinder and gauging plunger.
f. Use measured distance to select correct counter gear rear bearing shim.
Allowable counter gear end play:..................0 - 0.2 mm (0 - 0.008 inch)
3. Place suitable shim with grease on counter gear rear bearing.
4. Apply ATE to each part in front case.
5. Assemble center case assembly.
a. Install mainshaft on center case by tapping lightly.
Apply ATF to mainshaft front bearing.
b. Install bearing retainer.
16 - 21 Nm (1.6 - 2.1 kg.m, 12 -15 ft. lbs.)
c. Put drive chain onto the front drive sprocket and front drive shaft, and then put them in center case.
d. Install front drive shaft by tapping.
Make sure shafts are aligned in the case.
e. Apply ATF to needle bearings and install them into front drive sprocket.
These needle bearings can be installed more easily if front drive sprocket is rotated while installing them.
f. Install 2-4 coupling sleeve with 2-4 shift fork.
Pay special attention to direction of coupling sleeve.
g. Install shifting inserts and spread spring.
Pay attention to the direction of shifting inserts.
h. Install baulk ring, then install clutch gear and mainshaft rear bearing.
Place wooden block under mainshaft in order to protect mainshaft front bearing.
i. Install spacer.
j. Select and install snap ring with proper thickness.
Allowable clearance between snap ring and groove:................0 - 0.15 mm (0 - 0.0059 inch)
k. Install steel ball, speedometer drive gear and retainer ring.
Steel ball is the smallest of check balls for this unit.
l. Install low gear and its bearing onto mainshaft.
Apply ATF to needle bearing.
m. Install L & H hub and snap ring to mainshaft.
Pay attention to direction of L & H hub.
n. Measure low gear end play.
Standard:..................0.2 - 0.35 mm (0.0079 - 0.0138 inch)
6. Apply sealant to mating surface of center case then attach to front case and tighten bolts.
Use genuine anaerobic liquid gasket, Three Bond TB1215, Loctite Part No. 51813 or equivalent.
7. Install snap ring to 2-4 shift rod.
8. Install oil gutter and oil cover.
9. Apply ATF to each part in center case.
10. Apply sealant to mating surface of rear case then attach it to center case and tighten bolts.
Use genuine anaerobic liquid gasket, Three Bond TB1215, Loctite Part No. 51813 or equivalent.
11. Install 4WD switch.
Apply sealant to switch threads.
Use genuine anaerobic liquid gasket, Three Bond TB1215, Loctite Part No. 51813 or equivalent.
12. Install the companion flange and the companion flange nut. Tighten the companion flange to specification.