Assembly

1. Using press and Special Tool (A) 09951-76010, press-fit needle bearing into center case. As shown in the figure, apply straightedge to top surface of case and press-fit till limit line of special tool aligns with bottom surface of straightedge (i.e., case surface).

NOTE:
- Press-fitting needle bearing according to above procedure will set needle bearing 3 mm before it hits case bottom.
- Once it is press-fit all way down to case bottom, removal would be very difficult if it becomes necessary.





2. Using Special Tool (B) 09913-75520 and hammer, drive oil seal into center case until it becomes flush with case surface. Apply Grease "A" to oil seal lip.





3. Applying thread lock cement "B" and install oil gutter and tighten bolt (a) to 6 Nm (48 inch lbs.)





4. Using Special Tool (A) 09951-76010 and press, install needle bearing into rear case. As shown in the figure, apply straightedge to case surface and press-fit till top of special tool aligns with bottom surface of straightedge (i.e., case surface).

NOTE: As with needle bearing in center case, above installation procedure will set needle bearing at a position 3 mm before it hits case bottom.





5. Using Special Tool (B) 09913-75520 and hammer, install oil seal into rear case until it becomes flush with case surface. Apply grease "A" to oil seal lip.





6. Apply thread lock cement "B" to bolt, install rear case plate and bolt and tighten to (b) 6 Nm (48 inch lbs.)

NOTE: Removal of rear case plate is not required normally. However, if it is removed or replaced, install it with bolt applied with thread lock cement.





7. Using press and Special Tool (C) 09913-84510 and (D) 09925-18010, install bearings to front shaft.
Bearings for both front and rear are identical.





8. Using plastic hammer, drive output front shaft assembly into center case.





9. Using press and Special Tools (D) 09925-18010 (E) 09940-53111, install bearing No. 1 into output rear shaft. Place circlip portion of bearing on top as shown in the figure.





10. Install needle bearing, output low gear, reduction clutch hub onto output rear shaft and secure them with circlip. Hub has no specific installing direction.





11. Combine Special Tools (D) 09925-18010 and (E) 09940-53111 and press fit output rear shaft assembly into center case.

NOTE: Use Special Tool (F) 09951-26010 with its under-cut side faced down (toward bearing).





12. Install fork to corresponding shift shaft.





13. As shown in the figure, fit front drive clutch hub and sleeve.

NOTE:
- Sleeve with straight spline has no specific direction in dimension. However, it is recommended to install it facing its circumferential groove mark inward as it was originally so.
- With hub, its punch mark should face vehicle rear side (so that it can be seen).





14. Install front drive fork shaft assembly and sleeve & hub together into center case all at once. Then put locating ball and spring also into case and loosely install bolt.





15. Install sprocket to output rear shaft and apply drive chain.





16. Install needle bearing and bush to sprocket. Also, install steel ball, using care not to drop it.

NOTE:
- Point mark on output rear shaft between positions of bearing No. 2 and speedometer drive gear indicates steel ball location in the front.
- Point mark on bush flange also means position where steel ball is met.





17. Using Special Tools (D) 09925-18010 and (G) 09926-68310, press-fit bearing No. 2 into output rear shaft. It is necessary to place support base at lower end of shaft.





18. After installing large size circlip, install speedometer drive gear and secure it with small size circlip.





19. Install interlock steel ball.





20. Fit reduction clutch hub and sleeve.

NOTE:
- Sleeve used here is identified by tapered splines which make it different from front drive clutch sleeve.
- Circumferential groove mark (thicker rail side which works as shift stopper) should be inside (rear).
- Hub has no specific direction.





21. Combine sleeve & hub to reduction shift shaft assembly and install them into center case. Then put locating ball and spring also into case and loosely install bolt.
22. With sealant "C" applied to rubber plug, insert it into hole in case.

NOTE: When installing reduction shift shaft, front drive shift shaft must be placed at 4WD position.





23. If friction ring has been removed from counter shaft, press-fit new one onto shaft with Special Tool (K) 09913-80112. Use care so that it is installed in proper direction and position as shown in the figure.
Installing position "a": 39.5 mm (1.56 inch)





24. Install needle bearing, spacer, counter gear, steel balls and washers onto shaft.





25. Install counter shaft assembly into case. If O-ring has been removed, install new O-ring onto shaft and apply Grease "A". Also, install low gear needle bearing.





26. With circlip placed on input gear, press-fit input gear bearing using the following Special Tools:
(D) 09925-18010
(E) 09940-53111
(H) 09900-06107
27. Fix bearing with circlip.





28. Using Special Tool (B) 09913-75520, install oil seal to front case so that end surface of oil seal becomes flush with that case. Apply Grease "A" to oil seal lip.





29. Using Special Tool (I) 09951-16080, drive input gear assembly into front case.





30. Fix with circlip by means of Special Tool (J) 09900-06108 (snap ring pliers).





31. Oil to rotating parts and clean mating surfaces of both center and front cases.
32. Apply sealant "C" to mating surface of front case evenly and put cases together.

NOTE:
- For smooth installation of front case, apply grease to counter shaft O-ring.
- When mating front case, make sure that input gear meshes with counter gear first.





33. Torque 9 front case bolts to (d) 23 Nm (17.0 ft. lbs.).
34. Torque counter shaft plate fixing bolt applied with thread lock cement "B" to (c) 23 Nm (17.0 ft. lbs.).

NOTE:
- After tightening bolts, check input gear and output rear shaft for smooth rotation by hand at low and high speed position.
- Also check front drive shift for proper operation.





35. Before assembling rear case, shim adjustment is required.
Follow steps described below:





1. Measure rear case dimension A (from mating surface to bearing bore bottom) by using straight edge and vernier caliper.
Width of straight edge D plus A is obtained.





2. Place straight edge on bearing No. 2 securely and measure bearing height B (from center case mating surface to No. 2 bearing top).

CAUTION: Bridging straight edge between No. 2 bearing and output front shaft bearing brings misreading.

3. Obtain clearance C in following calculation.
C = (A + D) - (B + D)





4. Select a shim from among following available sizes and install it in bearing bore of rear case.

CAUTION: Installing of over sized shim beyond specification in the following table may cause tight rotation of rear shaft and consequential bearing damage.





36. Clean mating surfaces of both center and rear cases again, apply sealant "C" to mating surface of rear case, and put them together.





37. Torque 15 rear case bolts to (e) 23 Nm (17.0 ft. lbs.).

NOTE: After tightening bolts, provisionally install universal joint flange into rear shaft and check to make sure smooth rotation of shaft.





38. With reduction shift shaft shifted to left (at high speed side) as shown in the figure, fit yoke to shaft and fix it with spring pin.

NOTE: Be careful not to let spring pin fall off.

39. Torque locating spring bolts of shifters to (f) 26 Nm (19.0 ft. lbs.)





40. Install steel balls and 4WD/4WD-LOW switches.
Tightening Torque (g) 20 Nm (14.5 ft. lbs.)
41. Fix lead of 4WD switch with clamp.





42. Apply grease "A" to select return system parts and install them. Then torque select return spring bolt to (h) 35 Nm (25.5 ft. lbs.).
43. Clean mating surfaces of both gear shift lever case and rear case, and with sealant "C" applied to mating surface of gear shift lever case, push both cases together.
44. Torque gear shift lever case bolts to (i) 13 Nm (114 inch lbs.)
45. Install gear shift control lever temporarily and check to make sure that it shifts to each shift position smoothly. Also check shaft for rotation.





46. Confirm 4WD switch has turned ON at 4WD position (4H and 4L).
47. Confirm 4WD low switch has turned ON at 4WD low and Neutral position.
48. Upon completion of above checks, remove shift control lever.