Part 2

Transfer Assembly: Disassembly and Assembly

Part 2

20) Install the oil pump assembly to the mainshaft.
21) Install the snap ring to the mainshaft, using suitable tool.

CAUTION:
Do not reuse snap ring.

22) Install the retainer to the mainshaft.

CAUTION:
Set the projection of oil pump assembly to the identification hole, and then align locating hole of retainer to the L-H shift rod assembly.

23) Install the mainshaft rear bearing to the mainshaft, using Tool.

CAUTION:
Do not push too hard in order to avoid snap rings becoming dislodged from mainshaft.

24) Install the snap ring to the mainshaft, using suitable tool.

CAUTION:
Do not reuse snap ring.

25) Install the spacer to the control shift rod (A/T models only).
26) Apply liquid gasket to the mating surface of the front case.

- Use Genuine Anaerobic Liquid Gasket or equivalent. Refer to [Recommended Chemical Products and Sealants] Recommended Chemical Products and Sealants.

CAUTION:
Remove old sealant adhering to mating surfaces. Also remove any moisture, oil, or foreign material adhering to application and mating surfaces.

27) Install the rear case to the front case.
28) Tighten the bolts to the specified torque. Refer to [Transfer Assembly: Exploded View] Exploded View.

CAUTION:
Be sure to install the harness brackets and air breather hose clamp.

29) Install the retainer bolts with new gaskets. Tighten the bolts to the specified torque. Refer to [Transfer Assembly: Exploded View] Exploded View.

CAUTION:
- Do not reuse gasket.
- Tighten them to the specified torque again.

30) Apply petroleum jelly to the circumference of the oil seal, and install it to the front case, using Tools.

CAUTION:
- Do not reuse oil seal.
- Apply petroleum jelly to oil seal.

31) Install the rear oil seal until it is flush with the end face of the rear case, using Tool.

CAUTION:
- Do not reuse oil seal.
- Apply petroleum jelly to oil seal.

32) Install the oil cover until it reaches the end face of the new dust cover.

CAUTION:
Position the oil cover with the notch at bottom position.

33) Apply petroleum jelly to the circumference of the new dust cover. Position the dust cover as shown.

CAUTION:
- Do not reuse dust cover.
- Position the protrusions at the position shown.
- (1): Dust cover
- (A): Protrusions
- (2): Rear case assembly

34) Install the dust cover to the rear case, using Tool.

CAUTION:
- Do not reuse dust cover.
- Apply petroleum jelly to dust cover.

35) Install check ball and check spring to rear case (M/T models only).
36) Apply sealant to thread of check plug, then install it to rear case and tighten to the specified torque (M/T models only). Refer to [Transfer Assembly: Exploded View] Exploded View.

- Use Genuine Silicone RTV or equivalent. Refer to [Recommended Chemical Products and Sealants] Recommended Chemical Products and Sealants.

CAUTION:
Remove old sealant and oil adhering to threads.

37) Apply sealant to the threads of the wait detection switch (gray). Then install it to the rear case and tighten to the specified torque. Refer to [Transfer Assembly: Exploded View] Exploded View.

- Use Genuine Silicone RTV or equivalent. Refer to [Recommended Chemical Products and Sealants] Recommended Chemical Products and Sealants.

CAUTION:
Remove old sealant and oil adhering to threads.

38) Apply sealant to the threads of the 4LO switch (gray with green paint) and ATP switch (black). Then install them to the front case and tighten to the specified torque. Refer to [Transfer Assembly: Exploded View] Exploded View.

CAUTION:
- Do not reuse oil seal.
- Apply petroleum jelly to oil seal.

40) Align the matching mark on the front drive shaft with the mark on the companion flange, then install the companion flange.

41) Install the companion flange self-lock nut. Tighten to the specified torque, using suitable tool. Refer to [Transfer Assembly: Exploded View] Exploded View.

CAUTION:
Do not reuse self-lock nut.

42) Install the O-ring to the transfer control device.

CAUTION:
- Do not reuse O-ring.
- Apply petroleum jelly to O-ring.

43) Install the transfer control device to the rear case.

a) Turn the control shift rod fully counterclockwise using a suitable tool, and then put a mark on the control shift rod.
b) Align the transfer control device shaft cutout with the mark on the control shift rod, and install it.

NOTE:
Turn the transfer control device when the transfer control device connection does not match.

c) Tighten the bolts to the specified torque. Refer to [Transfer Assembly: Exploded View] Exploded View.

44) Install the drain plug and filler plug with new gaskets to the rear case. Tighten to the specified torque. Refer to [Transfer Assembly: Exploded View] Exploded View.

CAUTION:
Do not reuse gaskets.