Reassembly

Reassembly





1) Using press and special tool, press-fit needle bearing into center case (1). As shown in figure, apply straightedge (2) to top surface of case and press-fit till limit line (3) of special tool aligns with bottom surface of straightedge (2) (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 and hammer, drive oil seal (1) into center case (2) until it becomes flush with case surface. Apply grease "A" to oil seal lip.





3) Install oil gutter to center case (2) and tighten bolt (1) applying thread lock cement "B".





4) Using special tool and press, install needle bearing into rear case (1). As shown in figure, apply straightedge (2) to case surface and press-fit till top (3) of special tool (A) aligns with bottom surface of straightedge (2) (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 and hammer, install oil seal (1) into rear case (2) until it becomes flush with case surface. Apply grease "A" to oil seal lip.





6) Install rear case plate (1) and bolt (2) applying thread lock cement "B".

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 tools, install bearings (2) to front shaft (1). Bearings for both front and rear are identical.





8) Using press, drive output front shaft assembly (2) into center case (1).





9) Using press and special tools, install bearing No. 1 (1) into output rear shaft (2). Place circlip portion of bearing on top as shown in figure.





10) Install needle bearing (3) and output low gear (4) and then press-fit reduction clutch hub (5) onto output rear shaft (1) by using press and special tool and secure them with circlip (6). Hub has specific installing direction.





11) Combine special tools and press-fit output rear shaft assembly into center case (1).

NOTE: Use special tool (F) with its under-cut side faced down (toward bearing).





12) Install fork to corresponding shift shaft.





13) Fit sleeve to front drive clutch hub (1), place 3 synchronizer keys (4) (if equipped) in it and then set synchronizer springs (3) (if equipped). When installing, note that front drive clutch hub (1) and sleeve (2) have specific installing direction.

NOTE: Make sure that bent end of synchronizer spring is inserted into hole (if equipped).





14) Install front drive fork shaft assembly (5) and sleeve (7) and hub (8) together into center case all at once. Then put locating ball (4) and spring (3) also into case and loosely install bolt (1).





15) With the outer ring (5), spring (4) (if equipped), cone (6) and the inner ring (7) put together and installed to sprocket gear (2) as shown in figure, install them together with chain (3) to output rear shaft (1).





16) Install needle bearing (3) and bush (4) to sprocket (2). Also install steel ball (1), 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) Install synchronizer plate (1).





18) Using special tool, press-fit bearing No. 2 (1) into output rear shaft. It is necessary to place support base at lower end of shaft.





19) After installing large size circlip (4), install speedometer drive gear (3) and secure it with small size circlip (2).





20) Install interlock steel ball (1).





21) Fit sleeve (2) to reduction clutch hub (1).

NOTE:
^ Circumferential groove mark (thicker rail side which works as shift stopper) should be inside (rear).
^ Hub has no specific direction.

22) Combine sleeve (8) and hub to reduction shift shaft assembly (6) and install them into center case (9). Then put locating ball (4) and spring (3) also into case and loosely install bolt (1).





23) With sealant applied to rubber plug (5), insert it into hole in case.

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





24) If friction ring (2) has been removed from counter shaft (1), press-fit new one onto shaft, using care so that it is installed in proper direction and position as shown in figure.





25) Install needle bearing (3), spacer (4), counter gear (2), steel balls (5) and washers (1) onto shaft (6).

NOTE: Washers must be installed with its oil slot side facing gear.





26) Install counter shaft assembly into case. If O-ring (5) has been removed, install new O-ring onto shaft (3) and apply grease "A". Also, install low gear needle bearing (1).
27) With circlip (2) placed on input gear (1), press-fit input gear bearing (3).





28) Fix bearing with circlip (4).





29) Install oil seal (1) to front case (2) so that end surface of oil seal becomes flush with that case. Apply grease "A" to oil seal lip.





30) Using special tool, drive input gear assembly (2) into front case (1).





31) Fix with circlip (1) by means of snap ring pliers.
32) Oil to rotating parts and clean mating surfaces of center case (1) and front case (2).





33) Apply sealant "C" to mating surface of front case (2) 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.

34) Torque 9 front case bolts (2) to specification.





35) Torque counter shaft plate fixing bolt (1) applied with thread lock cement to specification.

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.

"B": Cement 99000-32020
Tightening torque
Countershaft plate bolt (c): 23 Nm (2.3 kgf-m, 17.0 ft. lbs.)
Front case bolt (d): 23 Nm (2.3 kgf-m, 17.0 ft. lbs.)





36) Before assembling rear case (2), shim adjustment is required. Follow steps described below.





a) Measure rear case (1) dimension "A" (from mating surface to bearing bore bottom) by using straightedge (2) and vernier caliper. Width of straightedge "D" plus "A" is obtained.
b) Place straightedge on bearing No. 2 (2) securely and measure bearing height "B" (from center case (1) mating surface to No. 2 bearing top).

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

c) Obtain clearance "C" in the following calculation. "C", = ("A" + "D") - ("B" + "D")
d) Select a shim from among the 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.





Shim specification





37) Clean mating surfaces of both center (2) and rear (1) cases again, apply sealant "C" to mating surface of rear case, and put them together.





38) Torque 15 rear case bolts (2) to specification.

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





39) For transfer for TYPE 2 manual transmission, perform the following procedure.
a) With reduction shift shaft shifted to high speed side, fit yoke to shaft and install return spring (2) as shown in figure. Tighten bolt (1) to specified torque.
Tightening torque
Select return spring bolt (TYPE 2 M/T) (f): 5.5 Nm (0.55 kgf-m, 4.0 ft. lbs.)
b) Fix reduction shift yoke with spring pin (4) while aligning shift yoke with shift shaft as shown in figure.





40) For transfer for A/T and TYPE 1 manual transmission, perform the following procedure.
a) With reduction shift shaft (1) shifted to left (at high speed side) as shown in figure, fit yoke (2) to shaft (1) and fix it with spring pin.

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

b) Torque locating spring bolts (4) of shifters to specification.





41) Install steel balls (1) and 4WD (2)/4WD-LOW switches.
42) Fix lead of 4WD switch (1) with clamp.
43) Apply grease "A" to select return system parts and install them. Then torque select return spring bolt (5) to specification (For transfer with A/T or TYPE 1 manual transmission only).
"A": Grease 99000-25010
Tightening torque
Select return spring bolt (A/T or TYPE 1 M/T) (i): 35 Nm (3.5 kgf-m, 25.5 ft. lbs.)
44) Clean mating surfaces of both gear shift lever case (7) and rear case, and with sealant "C" applied to mating surface of gear shift lever case, push both cases together.
"C": Sealant 99000-31110





45) Torque gear shift lever case bolts to specification.
Tightening torque
Gear shift lever case bolt (j): 13 Nm (1.3 kgf-m, 9.5 ft. lbs.)
46) Install gear shift control lever temporarily and check to make sure that it shifts to each shift position smoothly. Also check shaft for rotation.





47) Confirm 4WD switch (2) has turned ON at 4WD position (4H and 4L) by using ohmmeter (1).





48) Confirm 4WD LOW switch has turned ON at 4WD LOW and Neutral position.
49) Upon completion of above checks, remove shift control lever.