Unit Assembly

Unit Assembly
1) Put main shaft-input shaft assembly (7) into lower case (6), apply oil to component parts and check for proper engagement (smooth rotation) with counter shaft.

NOTE: For vehicle equipped with scissors gears, align paint match marks (1) marked before disassembly as shown in figure when installing main shaft to lower case (6).





2) After cleaning mating surfaces of both cases, coat mating surface of upper case (8) with sealant evenly and put it over lower case (6). At this time, all gears and forks should be set to neutral position.
"A": Sealant 99000-31150





3) Place bolts at their positions and check to make sure that their height from case surface is the same before tightening them. Also, check clamp position and torque them to specification.





4) Apply sealant "A" to mating surface of input shaft bearing retainer (1) and its bolts (2), then install them.





5) Install clutch housing (1) and torque its bolts (2) to specification.





6) Install release bearing
7) Clean mating surfaces of both cases, coat mating surface (1) of rear case with sealant evenly and mate it with transmission itself.





8) Install 12 rear case bolts and torque them to specification.
9) Install back up light switch (1).





10) Install gear shift lever case (4) temporarily to confirm switch function by checking the following.
Back up light switch (1) should conduct when gear shift control lever (3) is at reverse position.
11) After confirming switch function, remove gear shift lever case.
12) Connect transfer assembly to transmission and tighten its fastening bolts to specified torque.
Tightening torque
Transfer to transmission bolt (a): 23 Nm (2.3 kgf-m, 17.0 ft. lbs.)
13) With sealant applied to mating surface of transmission gear shift lever case assembly (5), put it onto transmission and transfer assembly, and torque bolts to specification.
"A": Sealant 99000-31110
Tightening torque
Gear shift case bolt (b): 13 Nm (1.3 kgf-m, 9.5 ft. lbs.)
14) Install breather hoses (4) for transmission and transfer and set clamps.
15) Connect wiring harness (3) to each coupler of 4WD switch, 5th switch and back up light switch.





16) Clamp wiring harness (3) and breather hoses (4) securely.

CAUTION: Fill specified amount of gear oil to transmission and transfer after remounting transmission and transfer assembly to vehicle.