Gear Sensor/Switch: Testing and Inspection
Transfer 4WD Switch InspectionReference: Transfer 4WD Switch Removal and Installation: Lever-Shift Type
1. Undo clamp and disconnect coupler of 4WD switch.
2. Function of transfer 4WD switch (2) can be checked as shown in the figure. There should be conduction at these terminals when shift lever is shifted to "4H", and "4L" positions.
3. Upon completion of check, connect coupler and clamp wiring harness as they were.
NOTE: When replacing switch(s), use care not to let dust enter transfer through switch hole.
Transfer Rear Case Oil Seal Removal and Installation
Removal
1. Remove rear propeller shaft referring to Propeller Shaft Removal and Installation.
2. Using flat end rod or the like, remove oil seal (1) from transfer rear case (2).
Installation
1. Using special tool and plastic hammer, press fit new oil seal (2) up to transfer rear case (1) surface. Be sure to apply grease to oil seal lip.
"A": Grease 99000-25010
Special Tool (A): 09940-53111
2. Install rear propeller shaft referring to Propeller Shaft Removal and Installation.
Transfer Center Case Oil Seal (Front Side) Removal and Installation
Removal
1. Remove front propeller shaft referring to Propeller Shaft Removal and Installation.
2. Using flat end rod or the like, remove oil seal (1) from transfer center case (2).
Installation
1. Using special tool and plastic hammer, press fit new oil seal (2) up to transfer center case (1) surface. Be sure to apply grease to oil seal lip.
"A": Grease 99000-25010
Special Tool (A): 09940-53111
2. Install front propeller shaft referring to Propeller Shaft Removal and Installation.
Speed Sensor Removal and Installation
Removal
1. Lift up vehicle horizontally or rear up.
2. Disconnect speed sensor coupler (1).
3. Remove bolt and take off speed sensor assembly (3) from transfer (2).
Installation
1. Make sure that O-ring and speed sensor have not been damaged.
2. Inspect speed sensor driven gear for abnormal wear of gear teeth or bend of shaft portion and replace it if necessary.
3. Make sure that speed sensor driven gear is smooth rotation.
4. Install speed sensor assembly (1) to transfer (2) and connect coupler (3) as it was.
Tightening torque
Speed sensor mounting bolt a: 6 Nm (0.6 kg-m, 4.5 ft. lbs.)
Engine Rear Mounting Replacement
Refer to Manual Transmission Assembly Dismounting and Remounting: H25 Engine Model.
Transfer Assembly Dismounting and Remounting
Dismounting and remounting of transfer and transmission together as a unit is described in Manual Transmission Assembly Dismounting and Remounting:H25 Engine Model or Automatic Transmission (with Transfer If Equipped) Dismounting and Remounting: 4 A/T, but it is also possible to dismount and remount transfer assembly by itself as described below.
Dismounting
1. In engine room
a. Disconnect negative (-) cable from battery.
b. Place wood block (1) between intake manifold (2) and dash panel (3) so that it serves as stopper when engine, transmission and transfer unit hangs down as rear mounting member is removed.
CAUTION: Make sure to use wood block (1) to prevent contact which may occur between the following parts.
^ Dash panel (3) and intake manifold (2)
^ Cooling fan and its shroud
2. In cabin
a. Remove console box.
b. Remove transmission and transfer shift control levers referring to Transmission Shift Control Lever Removal and Installation: H25 Engine Model and Transfer Shift Control Lever Removal and Installation: Lever-Shift Type.
3. On lift
a. Drain transfer oil referring to Transfer Gear Oil Inspection and Change:Lever-Shift Type.
b. Remove rear propeller shaft and front propeller shaft referring to Propeller Shaft Removal and Installation.
c. Disconnect exhaust No. 2 pipe referring to Exhaust System Components.
d. Disconnect speed sensor referring to Speed Sensor Removal and Installation: Lever-Shift Type.
e. Place transmission jack (1) and remove mounting member (2).
f. Lower transmission jack (1) gradually and check to ensure that wood block serves as stopper between engine and dash panel.
g. Remove bolts (4) for gear shift lever case (3).
h. Pull off breather hose.
4. In cabin
a. Remove gear shift lever case and then remove transfer front case bolt (1).
5. On lift
a. Remove transfer mounting (engine rear mounting (1)) by removing bolts (2).
b. Apply transmission jack (3) to transfer (2) to support it.
c. Remove couplers for 4WD / 4WD -LOW switches lead.
d. Remove transfer front case bolts (1).
e. With transfer assembly (2) supported with transmission jack (3), slide it rearward and when it is apart from transmission, lower it.
Remounting
For remounting, reverse dismounting procedure, noting the following.
^ Be sure to use specified torque for tightening. Refer to Engine Rear Mounting Replacement: Lever-Shift
Type, Exhaust System Components and Propeller Shaft Removal and Installation.
^ Clamp wiring and breather hose securely.
^ Clamp shift lever boot securely.
^ Fill specified gear oil referring to Transfer Gear Oil Inspection and Change:Lever-Shift Type.
^ Connect battery and check for function.
Transfer Disassembly
Reference: Transfer Assembly Dismounting and Remounting: Lever-Shift Type
1. Remove 4WD switch (3) and take out steel ball.
2. Remove 5 bolts and then remove transfer rear cover (1) (if equipped), transfer damper bracket (2) and gear shift lever case (4).
3. For transfer for A/T, after removing bolt of select return system, take out spring (4), steel ball (5) and pin (6).
4. For transfer for manual transmission, remove select return spring bolt (1) and then return spring (2).
5. Drive spring pin out of reduction shift yoke by hammering special tool.
NOTE:
^ Pin may drop into case when driven out. Therefore, take it out when case is disassembled.
^ After spring pin is removed, yoke may be either taken out.
Special Tool (A): 09922-85811
6. Remove 15 rear case bolts, and then separate case by using special tool.
NOTE: To separate center case (1) and rear case (2), use special tool at 4 points in turn and make opening wider evenly.
Special Tool (B): 09912-34510
7. Remove circlip (1) from output rear shaft (2) by using screwdrivers and hammer, then pull out speedometer drive gear (3) and steel ball.
NOTE: Watch out for steel ball which comes off from shaft when speedometer drive gear is pulled out so as not to lose it.
8. Remove circlip for bearing and pull out output rear shaft No. 2 bearing (1) by combination of special tools.
Special Tool
(c): 09921-57810
(D): 09927-18411
9. Remove synchronizer plate screws (2) and pull out sprocket bush (4) and needle bearing (3) from output rear shaft (5).
10. Remove drive sprocket (6) with drive chain (7) and synchronizer plate (1).
NOTE: Watch out for steel ball which comes off from shaft when bush is pulled out so as not to lose it.
11. Remove counter shaft plate bolt (1) from front case (3), and counter shaft plate will come off.
12. Remove front case (3) by removing its 9 bolts (2).
13. Remove input gear needle bearing (1).
14. Remove counter gear shaft (3) together with counter gear (2), needle bearings, function ring, washers (4) and steel balls (5) from case.
NOTE:
^ Watch out for steel balls (5) which come out from between shaft (3) and washers (front and rear) (4) so as not to lose them.
^ Check friction ring lip for damage and wear. Replace if necessary.
^ Neither O-ring nor friction ring should be removed unless absolutely necessary. If removed, use new parts for reinstallation. Removed ones should not be reused.
15. Remove 0-ring from counter gear shaft (2) and then remove friction ring (3) from shaft, using a proper size rod (1) and hydraulic press.
16. Remove locating spring bolt (1) with washer (2) (if equipped), spring (3) and ball (4) for reduction shift.
17. Pull out reduction shift shaft (6) together with fork (7) and sleeve (8).
NOTE: For this removal, be sure to place front drive fork shaft at 4WD position.
18. Remove rubber plug (5), and then remove interlock steel ball (9) from rubber plug hole.
19. Remove locating spring bolt (1) with washer (2) (if equipped), spring (3) and ball (4) for front drive shift.
20. Pull out front drive shift fork (6) and shaft (5), sleeve (7) and hub (8) all together.
21. Using plastic hammer (2), drive out output rear shaft assembly (1) with bearing. Output low gear and reduction clutch hub also come off as they are installed to shaft.
22. Pull off circlip from output rear shaft and remove reduction clutch hub (1) by using puller (2) and hydraulic press. Then pull out output low gear and needle bearing.
23. Using puller (3) and hydraulic press, remove output rear shaft No. 1 bearing (2) from shaft (1).
24. Remove oil seal from center case (1).
25. Using plastic hammer, drive out output front shaft (2) together with bearings.
CAUTION: If oil seal remains in center case, be careful not to damage oil seal by hitting. Use drive punch for hammering.
26. Take off bearings (1, 3) from shaft by using hydraulic press and puller (2). Removal of front side bearing requires special tool additionally as shown in the figure.
Special Tool (E): 09925-98221
27. To remove needle bearing (2) from center case (1), combine special tools as shown in the figure and press them.
Special Tool
(F): 09913-84510
(G): 09941-64511
28. Remove oil seal from rear case (1). And then, using special tools and hydraulic press, remove needle bearing (2) from rear case.
CAUTION: Be careful not to damage oil seal, if it remains in rear case.
Special Tool
(F): 09913-84510
(G):09941-64511
29. Using special tool, remove circlip (3) of input gear (1) from front case (2).
Special Tool (H):09900-06108
30. Using plastic hammer, drive input gear (2) out of front case (1).
NOTE:
^ Be careful not to damage oil seal (3) by hitting.
^ If removed, do not reuse oil seal (3).
31. Remove circlip (2) of input gear (1) by using special tool.
Special Tool (1): 09900-06107
32. Remove bearing (2) from input gear (1) by using puller (3) and hydraulic press.
NOTE: Use metal pad for this removal, or gear spline may get damaged.
Special Tool(J): 09951-76010
33. With spring (3) on front drive fork shaft (4) compressed, remove circlip (1) and then remove fork (2) and spring (3).
34. Remove center case gutter (1) from center case (2) with using wrench.
Transfer Inspection
Reference: Transfer Assembly Dismounting and Remounting: Lever-Shift Type Reference: Transfer Disassembly: Lever-Shift Type
Check each ball bearing for smooth rotation. If found abnormal, replace.
^ Check needle bearing and bearing contacting surface for damage. Replace as required.
^ Check gear tooth surface and shift mechanism in the same manner as with transmission. Correct or replace as necessary.
^ Check each spring for distortion or breakage and change it with new one as necessary. Especially for locating springs (1), measure each free length and replace if it is below service limit.
Locating spring free length "a"
Standard: 19.5 mm (0.768 inch)
Service limit: 18.0 mm (0.709 inch)
^ Check drive chain and sprockets for abnormal wear or damage. Replace as required.
^ Check oil seal for leakage and its lip for excessive hardness. If either is found, replace. Also, check corresponding surface of shaft where oil seal lip contacts. Correct or replace as necessary.
^ Check gear tooth surface of speedometer drive gear. Replace if it is damaged.
^ Put the synchronizer outer ring (1), inner ring (3) center cone (2) and inner ring (3) together and then measure the step difference between the outer ring (1) and the inner ring (3). And also check key slot or boss width "c" in synchronizer outer ring (1) and each chamfered tooth of gear and synchronizer ring and replace with new one, if necessary. Also, check gear tooth.
Difference "b" between the outer ring and the inner ring
Standard: 1.0 - 1.4 mm (0.039 - 0.055 inch)
Service limit: 0.5 mm (0.020 inch)
Key slot or boss width "c" in synchronizer outer ring
Standard: 10.1 mm (0.398 inch)
Service limit: 10.4 mm (0.409 inch)
^ Check chamfered part of each sleeve (1) for damage and excessive wear, and replace as necessary.
^ Using feeler gauge, check clearance between sleeve (1) and shift fork (2) and replace parts if necessary.
Clearance "d" between sleeve and shift fork
Maximum 1.0 mm (0.039 inch)
^ Check each synchronizer key and synchronizer spring and replace as necessary.
^ Check splined portions and replace parts if excessive wear is found.