Part 3 of 3

4. Remove reverse check sleeve. Disassembly procedure is as follows:
1. Using a standard screwdriver, remove snap ring (A) (Inner-28).

NOTE:
Replace snap ring with a new one if deformed or weakened.

2. Remove reverse check plate (B).
3. Remove reverse check spring (C) with cam (D).
4. Remove reverse return spring (E).
5. Remove reverse accent shaft (F)
6. Remove O-ring (G).

NOTE:
^ Reverse check sleeve assembly uses an O-ring which should not be scratched.
^ Be careful not to break adjustment shim placed between reverse check sleeve assembly and case.





5. Remove back-up light switch (1).
6. Remove oil guide (2).

3. Extension





1. Remove extension cover (2) and shift bracket (1).
2. Remove snap ring (4) (Outer-30).
3. Remove transfer drive gear (5).

CAUTION:
Do not remove ball bearing unless replacing.

4. Remove snap ring (6) (Inner-72).
5. Remove ball bearing (7).

CAUTION: Do not reuse ball bearing.

6. Remove oil seal (8).

CAUTION: Do not reuse oil seal.

C: Assembly
1. Extension





1. Installation of ball bearing (1) and selection of snap ring (2) (Inner-72)
1. Attach ball bearing (1) (30 x 72 x 17) to extension and install snap ring (2).





2. Measure clearance between snap ring (2) and outer race of ball bearing (1) with a thickness gauge.

CAUTION: Replace ball bearing with a new one.

Clearance: 0 - 0.15 mm (0 - 0.0059 inch)





3. If the measurement is not within the specification, select suitable snap ring (2).





2. Installation of transfer drive gear (3)
Press transfer drive gear into inner race of ball bearing.





3. Selection of snap ring (4) (Outer-30)
1. Install snap ring (4) on transfer drive shaft.
2. Measure clearance between snap ring and inner race of ball bearing with a thickness gauge.

Clearance: 0 - 0.15 mm (0 - 0.0059 inch)





3. If the measurement is not within the specification, select suitable snap ring.





4. Install extension cover (6), gasket (6) and shift bracket (7).

CAUTION: Use new gasket.

5. Install oil seal (8) with Special Service Tool(SST).
(SST) 498057300 INSTALLER

CAUTION: Use new oil seal.

2. Transfer Case
Assembly of transfer case is in the reverse order of disassembly. Do the following:





1. Assembly of reverse check sleeve
1. Install reverse accent shaft (F), check cam (D), return spring (E) and check spring (C) onto reverse check sleeve.

NOTE:
Be sure the bent section of reverse check spring is positioned in the groove in check cam.

2. Hook the bent section of reverse check spring over reverse check plate (B).
3. Rotate cam so that the protrusion of reverse check cam is at the opening in plate.
4. With cam held in that position, install plate onto reverse check sleeve and hold with snap ring (A) (Inner-28).
5. Position O-ring (G) (35.4 x 1.5) in groove in sleeve.





CAUTION:
^ Make sure the cutout section of reverse accent shaft is aligned with the opening in reverse check sleeve.
^ Spin cam by hand for smooth rotation.
If it does not return properly, replace reverse check spring.
^ Move cam and shaft all the way toward plate and release.
If cam does not return properly, replace reverse check spring; if shaft does not, check for scratches on the inner surface of sleeve. If sleeve is in good order, replace spring.
^ Select a suitable reverse accent shaft and reverse check plate by referring to "Neutral Position Adjustment."





2. Installation of shifter arm (7) and selector arm (8) Install shifter arm into the partition from the front while inserting selector arm into the opening in reverse check sleeve. Pass shaft through hole in selector arm until its end comes out of the rear of transfer case.

NOTE:
Apply a coat of gear oil to shifter arm. Also make sure oil seal is positioned properly.

Tightening torque:
T1: 6.4 ± 0.5 N m (0.65 ±0.05 kg-m, 4.7 ± 0.4 ft. lbs.)
T2: 10 ± 1 Nm (1.0 ± 0.1 kg-m, 7.2 ± 0.7 ft. lbs.)
T3: 19.6 ± 1.5 Nm (2.00 ° 0.15 kg-m, 14.5 ± 1.1 ft. lbs.)
T4: 25 ± 2 Nm (2.5 ± 0.2 kg-m, 18.1 ± 1.4 ft. lbs.)

3. Combination Of Transfer Case And Extension Assembly





1. Install center differential (1) and transfer driven gear into transfer case.

Tightening torque:
T: 37 ± 3 Nm (3.8 ± 0.3 kg-m, 27.5 ± 2.2 ft. lbs.)





2. Selection of thrust washer (52 x 61 x t)
1. Measure height "W" between transfer case and ball bearing on the transfer driven gear (3).





2. Measure depth "X" as shown in figure.
(4) Extension
3. Calculate space "Y" using the following equation: Y = X - W + 0.24 mm (0.0094 inch) [Thickness of gasket]





4. Select suitable washer in the following table:

Standard clearance between thrust washer and ball bearing:
0.05 - 0.30 mm (0.0020 - 0.0118 inch)

5. Fit thrust washers on transfer drive shaft.





3. Install extension assembly into transfer case.

D: Installation





1. Install transfer case (20 with extension assembly (1).
2. Secure selector arm to shifter arm with shifter fork screw (3). Shifter arm should be caught by pawl of rod. Selector arm must be engaged with reverse check sleeve assembly.
3. Adjustment of neutral position
1. Shift gear into 3rd gear position.
2. Shifter arm turns lightly toward the lst/2nd gear side but heavily toward the reverse gear side because of the function of the return spring, until arm contacts the stopper.
3. Make adjustment so that the heavy stroke (reverse side) is a little more than the light stroke (1st/2nd side).





4. To adjust, remove bolts holding reverse check sleeve assembly (4) to the case, move sleeve assembly outward, and place adjustment shim (O to 1 ea.) between sleeve assembly and case to adjust the clearance.

CAUTION: Be careful not to break O-ring when placing shim(s).

- When shim is removed, the neutral position will move closer to reverse; when shim is added, the neutral position will move closer to 1st gear.





- If shims alone cannot adjust the clearance, replace reverse accent shaft and re-adjust.








4. Reverse check plate (5) adjustment
Shift shifter arm to "5th" and then to reverse to see if reverse check mechanism operates properly. Also check to see if arm returns to neutral when released from the reverse position. If arm does not return properly, replace reverse check plate.





5. Install transfer (6) cover and gasket.
6. Connect each connector (7).

6. FRONT DIFFERENTIAL
A: Disassembly





1. Remove right and left snap rings (10 from differential, and then remove two axle drive shafts (2).

NOTE:
During reassembly, reinstall each axle drive shaft in the same place from which it was removed.

2. Loosen twelve bolts (3) and remove hypoid drive gear (4).





3. Drive out straight pin (5) from differential assembly toward hypoid driven gear.
Special Service Tool (SST) 899904100 REMOVER





4. Pull out pinion shaft (6), and remove differential bevel pinion (7) and gear (8) and washer (9).





5. Remove roller bearing using (SST).
SST 399527700 PULLER SET

B: Assembly





1. Install bevel gear and bevel pinion together with washers, and insert pinion shaft (1).

NOTE:
Face the chamfered side of washer toward gear.








2. Measure backlash between bevel gear and pinion. If it is not within specifications, install a suitable washer to adjust it.

Standard backlash:
0.13 - 0.18 mm (0.0051 - 0.0071 inch)

SST1 498247001 MAGNET BASE
SST2 498247100 DIAL GAUGE

NOTE:
Be sure the pinion gear tooth contacts adjacent gear teeth during measurement.





3. Align pinion shaft and differential case at their holes, and drive straight pin (5) into holes from the hypoid driven gear side, using SST.
SST 899904100 REMOVER

NOTE: Lock straight pin after installing.





4. Install roller bearing (40 x 80 x 19.75) to differential case.

NOTE:
Be careful because roller bearing outer races are used as a set.

SST1 499277100 BUSH 1-2 INSTALLER
SST2 398497701 ADAPTER





5. Install hypoid driven gear (4) to differential case using twelve bolts (3).

Tightening torque:
62 ± 5 N m (6.3 ± 0.5 kg-m, 45.6 ± 3.6 ft. lbs.)





6. Position drive axle shaft in differential case and hold it with outer snap ring (28). Using a thickness gauge, measure clearance between the shaft and case is within specifications.

Clearance:
0 - 0.2 mm (0 - 0.008 inch)





If it is not within specifications, replace snap ring with a suitable one.

7. Center Differential
A: Disassembly





1. Remove snap ring (1) (Inner-110) using flat bladed screwdriver.
2. Remove center differential cover (2).
3. Remove snap ring (4) and roller bearing (3).
4. Remove viscous coupling (5).
5. Remove needle bearings (6).
6. Remove adjusting washer (7) (45 x 62 x t).
7. Remove pinion shaft (8), bevel pinions (9) and retainers (10).
8. Remove side gear (11).
9. Remove thrust washer (12).





10. Remove ball bearing (13) using Special Service Tool (SST).
(SST) 498077300 CENTER DIFFERENTIAL BEARING REMOVER

CAUTION:
Do not reuse ball bearing.

B. Assembly





Assembly is in the reverse order of disassembly. Do the following:
- Install thrust washer with chamfered side of inner perimeter facing the side gear.
- Install adjusting washer with chamfered side of inner perimeter facing the viscous coupling using SST.
SST 499547300 INSTALLER SET





1. Selection of snap ring (Inner-110)
1. After assembling, using a thickness gauge measure clearance between snap ring (1) and center differential case.

Clearance: 0 - 0.15 mm (0 - 0.0059 inch)





2. If the measurement is not within the specification, select suitable snap ring.





2. Selection of adjusting washer (Backlash adjustment)
1. After assembling, set up a SST1 and SST2 to end of viscous coupling shaft. Move viscous coupling up and down, and measure backlash in the axial direction.
SST1 498247001 MAGNET BASE
SST2 498247100 DIAL GAUGE

Backlash: 0.62 - 0.86 mm (0.0244 - 0.0339 inch)





2. If the measurement is not within the specification, select suitable washer.