Shift Link Assembly
Shift Link AssemblyREMOVAL
1) Remove the manual transmission assembly from the vehicle.
2) Remove the back-up light switch and the neutral position switch.
3) Remove the transfer case together with the extension case assembly.
4) Remove the extension case assembly.
5) Remove the center differential and transfer driven gear as a unit.
6) Pull out the straight pin.
7) Use the ST to remove the spring pin, and remove the selector lever COMPL.
ST 398791700 SPRING PIN REMOVER 2
8) Pull out the selector arm No. 2 from neutral set spring.
9) Remove the shifter arm collar and neutral set spring from transfer case.
10) Remove the shifter arm No. 2, washers and thrust bearing from transfer case.
11) Use the ST to remove the spring pin, and remove the shifter arm and selector arm.
ST 398791700 SPRING PIN REMOVER 2
12) Remove the oil seal from the transfer case by using a screwdriver wrapped with vinyl tape etc.
NOTE:
The illustration shows the oil seal of selector lever COMPL. Perform the same procedures for removing the shifter arm No. 2.
13) Remove the needle bearing from the transfer case by using a tube with the diameter of 20 mm (0.79 in) or 21 mm (0.83 in) and the ST.
ST 18763AA000 COMPRESSOR SHAFT
14) Set ST1, ST2 and transfer case to a press.
NOTE:
^ Set the ST2 under ST1.
^ Set the transfer case so that the hole for shifter arm is positioned vertically.
ST1 498267300 CYLINDER HEAD TABLE
ST2 498267200 CYLINDER HEAD TABLE
15) Remove the roller bearing by using a round bar with the diameter of 22 mm (0.87 in) or 23 mm (0.91 in).
16) Flip over the transfer case, and set an iron plate between transfer case and ST.
NOTE:
^ Insert the iron plate which is thicker than the exposed length of the transfer case knock pin between the ST and transfer case.
^ Set the iron plate so that the transfer case knock pin does not ride on the iron plate.
17) Remove the roller bearing by using a tube with the diameter of 22 mm (0.87 in) or 23 mm (0.91 in).
18) Remove the plunger and check ball spring from transmission cover.
INSTALLATION
1) Install the plunger and check ball spring to transmission cover.
NOTE:
Use a new seal ring.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
2) Using the ST, install the needle bearing to the transfer case.
NOTE:
^ Use a new needle bearing.
^ If the press-fit depth exceeds the service limit, replace with a new needle bearing.
ST1 18763AA000 COMPRESSOR SHAFT
ST2 498277200 STOPPER SET
Press-fit depth of needle bearing:
A: 8.5±0.2 mm (0.33±0.01 in) from the end of transfer case
B: 0.2±0.2 mm (0.01±0.01 in) from the end of transfer case
3) Set ST1, ST2 and transfer case to a press.
NOTE:
^ Set the ST2 under ST1.
^ Set the transfer case so that the hole for shifter arm is positioned vertically.
ST1 498267300 CYLINDER HEAD TABLE
ST2 498267200 CYLINDER HEAD TABLE
4) Using the ST, install the roller bearing to the transfer case.
NOTE:
^ Use a new bearing.
^ Gradually perform the press-fit operation while measuring the press-fit depth.
^ If the press-fit depth exceeds the service limit, replace with a new bearing.
ST 899864100 REMOVER
Press-fit depth of roller bearing:
A: 5.1±0.2 mm (0.20±0.01 in) from the finished surface of transfer case
5) Flip over the transfer case, and set an iron plate between transfer case and ST.
NOTE:
^ Insert the iron plate which is thicker than the exposed length of the transfer case knock pin between the ST and transfer case.
^ Set the parts while taking care that the transfer case knock pin and the roller bearing do not ride over the iron plate.
6) Using the ST, install the roller bearing to the transfer case.
NOTE:
^ Use a new bearing.
^ Gradually perform the press-fit operation while measuring the press-fit depth.
^ If the press-fit depth exceeds the service limit, replace with a new bearing.
ST 899864100 REMOVER
Press-fit depth of roller bearing:
A: 0±0.2 mm (0±0.01 in) from the end of transfer case
7) Using the ST, install the oil seal to the transfer case.
NOTE:
^ Use a new oil seal.
^ The illustration shows the oil seal of selector lever COMPL. Perform the same procedures for installing the shifter arm No. 2.
^ Apply transmission gear oil to the oil seal lips.
ST 18657AA000 INSTALLER
Press-fit depth of oil seal:
1±0.2 mm (0.04±0.01 in) from the end of transfer case
8) Insert the shifter arm into the selector arm, and fix with a spring pin.
NOTE:
Use new spring pin.
ST 398791700 SPRING PIN REMOVER 2
9) Install the shifter arm No. 2, washers and thrust bearing to transfer case.
10) Install the shifter arm collar and neutral set spring to transfer case.
NOTE:
Use a new gasket.
Tightening torque:
6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
11) Install the selector arm No. 2 to neutral set spring.
12) Insert the selector lever COMPL into the selector arm No. 2, and fix with a spring pin.
NOTE:
Use new spring pin.
ST 398791700 SPRING PIN REMOVER 2
13) Insert a new straight pin.
14) Apply liquid gasket seamlessly to the mating surface of transmission cover.
Liquid gasket:
THREE BOND 1215 (Part No. 004403007) or equivalent
15) Install the transmission cover to transfer case.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
16) Install the center differential and transfer driven gear as a unit.
17) Attach the extension assembly to the transfer case.
18) Install the transfer case and the extension case assembly.
19) Install the back-up light switch and the neutral position switch.
20) Install the manual transmission assembly to the vehicle.