Connection of Each Section

CONNECTION OF EACH SECTION





1. Install the parking pawl, shaft and return spring.





2. Install inlet filter to transmission case.





3. Install transfer valve plate, valve body and duty solenoid C (transfer) to transmission case.

CAUTION:
- Be sure to install transfer seal lip to transfer control valve body.
- If transfer seal lip is damaged, replace seal with new one.

Tightening torque: 8 ± 1 Nm (0.8 ± 0.1 kg-m, 5.8 ± 0.7 ft. lbs.)
4. Connect connector to duty solenoid C (transfer).





5. Install the reduction drive gear assembly.

NOTE: Insert it fully into position until the bearing shoulder bottoms.





6. Using a plastic hammer, install reduction driven gear assembly, and tighten drive pinion lock nut.

NOTE:
- Be sure to use a new lock nut and a washer.
- Set the select lever in the "P" range.
- After tightening, stake the lock nut securely.

Tightening torque: 98 ± 5 Nm (10.0 ± 0.5 kg-m, 72.3 ± 3.6 ft. lbs.)
7. Measurement and adjustment of extension end play





1. Measure distance L from end of extension case and rear drive shaft with ST.
ST 398643600 GAUGE
L= Measured value - 15 mm





2. Measure the distance "e" from the transmission case mating surface to the reduction drive gear end surface with ST1 and ST2. l = Measured value - 50 mm
ST1 398643600 GAUGE
ST2 499577000 GAUGE
3. Calculation equation:





NOTE: Add 0.05 mm (0.0020 inch) and 0.20 mm (0.0079 inch) thick shims to area "T". Calculate formula 2 to determine "H". The calculated "H" refers to the shim thickness range. Select shims of suitable thicknesses within the calculated "H" range.

T = (L + G) - l - H
T: Shim clearance
L: Distance from end of extension case to end of rear drive shaft
G: Gasket thickness (0.45 mm, 0.0177 inch)
l: Height from end of transmission case to end of reduction drive gear
H: Thrust needle bearing thickness 0.05 - 0.25 mm (0.0020 - 0.0098 inch)

8. Installation of extension case and transmission case
1. Attach the selected thrust needle bearing to the end surface of reduction drive gear with Vaseline.

CAUTION: Install thrust needle bearing in the correct direction. Refer to Location and Installing Direction of Thrust Needle Bearing. Location and Installing Direction of Thrust Needle Bearing

2. Install the extension case to the transmission case.

CAUTION: Be sure to use a new gasket.





3. Tighten bolts to secure the case.
Tightening torque: 25 ± 2 Nm (2.5 ± 0.2 kg-m, 18.1 ± 1.4 ft. lbs.)





9. Install the vehicle speed sensor 1 (rear).
Tightening torque: 7 ± 1 Nm (0.7 ± 0.1 kg-m, 5.1 ± 0.7 ft. lbs.)