Duty Solenoid C and Transfer Valve Body

A: REMOVAL





1. Remove pitching stopper.





2. Raise vehicle and drain ATF.





3. Remove front exhaust pipe. Disconnect oxygen sensor connector, and remove exhaust pipe.





4. Remove propeller shaft.

NOTE: Before removing propeller shaft, scribe matching marks on propeller shaft and rear differential coupling.





5. Remove rear crossmember.
1. Support transmission using a transmission jack and raise slightly.
2. Remove bolts and nuts as shown in Figure.





6. Remove vehicle speed sensor 1.





7. Remove extension and gasket.
1. Remove gear select cable nut.
2. Move gear select cable so that extension bolts can be removed.





3. Remove bolts.
4. Remove extension and disconnect duty solenoid C connector.

CAUTION: Do not force extension back before disconnecting solenoid connector. Otherwise, harness may be damaged.

NOTE:
Use a container to catch oil flowing from extension.





8. Remove duty solenoid C and transfer valve body from extension.
1. Remove transfer clutch drum.





2. Remove clamp which secures pipe
3. Remove bolts.

B: INSTALLATION





1. Install duty solenoid C and transfer valve body.
1. Install duty solenoid C and transfer valve body.

Tightening torque:
8 ± 1 Nm (0.8 ± 0.1 kg-m, 5.8 ± 0.7 ft. lbs.)

2. Install pipe and clamp.

Tightening torque:
8 ± 1 Nm (0.8 ± 0.1 kg-m, 5.8 ± 0.7 ft. lbs.)

3. Install clutch drum.





2. Install extension.
1. Connect connector.
2. Tighten 11 bolts.

Tightening torque:
25 ± 2 Nm (2.5 ± 0.2 kg-m, 18.1 ± 1.4 ft. lbs.)





3. Install gear select cable.

Tightening torque:
14 ± 4 Nm (1.4 ± 0.4 kg-m, 10.1 ± 2.9 ft. lbs.)





3. Install vehicle speed sensor 1.

Tightening torque:
7 ± 1 Nm (0.7 ± 0.1 kg-m, 5.1 ± 0.7 ft. lbs.)





4. Install rear crossmember.
1. Tighten bolts.

Tightening torque:
Crossmember to body
69 ± 15 Nm (7.0 ± 1.5 kg-m, 51 ± 11 ft. lbs.)
Crossmember to cushion
18 ± 5 Nm (1.8 ± 0.5 kg-m, 13.0 ± 3.6 ft. lbs.)

2. Lower and remove transmission jack.





5. Install propeller shaft.

Tightening torque:
At rear differential
23 ± 5 Nm (2.3 ± 0.5 kg-m, 16.6 ± 3.6 ft. lbs.)
At center bearing
39 ± 5 Nm (4.0 ± 0.5 kg-m, 28.9 ± 3.6 ft. lbs.)

NOTE:
Align matching marks on propeller shaft and rear differential coupling.





6. Install front exhaust pipe.

Tightening torque:
At engine
29 ± 5 Nm (3.0 ± 0.5 kg-m, 21.7 ± 3.6 ft. lbs.)
At hanger
29 ± 5 Nm (3.0 ± 0.5 kg-m, 21.7 ± 3.6 ft. lbs.)
At front and rear connections
18 ± 5 Nm (1.8 ± 0.5 kg-m, 13.0 ± 3.6 ft. lbs.)





7. Lower and remove jack.
8. Connect the following parts:
1. Oxygen sensor connector
2. Multi-connector





9. Install pitching stopper.

Tightening torque:
Body side
57 ± 10 Nm (5.8 ± 1.0 kg-m, 42 ± 7 ft. lbs.)
Engine side
49 ± 5 Nm (5.0 ± 0.5 kg-m, 36.2 ± 3.6 ft. lbs.)





10. Replenish ATF and check oil level. Check for leaks.