Assembly

ASSEMBLY OF TRANSFER











1. INSTALL HIGH GEAR TO REAR OUTPUT SHAFT
Using SST 09316-60010, press in the following parts:
- High gear bearing (ATM)
- High gear
- Output shaft front bearing
- Clutch hub




2. INSTALL LOW GEAR TO REAR OUTPUT SHAFT
Using SST 09316-60010, press in the following parts:
- Clutch sleeve
- Low gear bearing (ATM)
- Low gear
- Output shaft rear bearing




3. INSTALL SNAP RING
Select a snap ring that will allow minimum axial play and install it on the shaft.
Mark Thickness mm (in.)
11 2.30-2.35 (0.0906 - 0.0925)
17 2.60-2.65 (0.1024 - 0.1043)





4. INSTALL TRANSFER HIGH AND LOW SHIFT OUTER AND INNER LEVER




5. INSTALL FRONT OUTPUT SHAFT
Using SST, press in the front output shaft to the transfer front case. SST 09316-60010




6. INSTALL ADJUSTING SHIM TO TRANSFER FRONT CASE (ATM)
(a) Measure the difference of A and B (left), and select a shim of a thickness so the gap between the transfer adapter and front case is within the standard clearance.
Standard clearance: 0.4 - 0.5 mm (0.016 - 0.020 in.)
Adjusting shim thickness mm (in.)
2.28 - 2.32 (0.0898 - 0.0913)
2.38 - 2.42 (0.0937 - 0.0953)
2.48 - 2.52 (0.0976 - 0.0992)
(b) Install the adjusting shim to the transfer front case.




7. INSTALL TRANSFER FRONT CASE
(a) Apply MP grease to the oil seal.
(b) Install the front case with a new gasket to the transfer adapter.
(c) Apply liquid sealer to the bolts, and install and torque as shown.
4-Speed: Four bolts
5-Speed: Three bolts
Torque: 17 mm 650 kg-cm (47 ft-lb, 64 Nm)
14 mm 400 kg-cm (29 ft-lb, 39 Nm)
(d) Install and torque the other bolts.
Torque: 650 kg-cm (47 ft-lb, 64 Nm)




8. INSTALL SHIFT FORK SHAFT
[Mechanical Shift Type]
(a) Install the shift fork shaft into shift fork No.1.
(b) Using a pin punch and a hammer, drive in the slotted spring pin.

NOTE: Use a set of soft jaws in the vise to protect the shift fork.




[Electrical Shift Type]
(a) Using snap ring pliers, install the snap ring.




(b) Install the shift fork, spring and retainer to the shift fork shaft.
Torque: 185 kg-cm (14 ft-lb, 18 Nm)




9. INSTALL CLUTCH SLEEVE
Install the clutch sleeve with the shift fork and shift fork shaft.




10. INSTALL REAR OUTPUT SHAFT FRONT BEARING RETAINER
Using a plastic hammer, install the rear output shaft front bearing retainer.




11. INSTALL IDLER GEAR
(a) Install a new 0-ring on the idler gear shaft front side groove.
(b) Install the idler gear shaft to the transfer front case.
(c) Install the idler gear thrust washer.

NOTE: Be sure that protruding part of washer fits in the case groove.




(d) Apply MP grease to the two bearings.
(e) Install the two bearings and spacer to the idler gear shaft.
(f) Install the idler gear to the idler gear shaft.




12. INSTALL 0-RING TO TRANSMISSION OUTPUT SHAFT (ATM)




13. INSTALL TRANSFER INPUT GEAR
Using SST, install the transfer input gear. SST 09309-36033




14. INSTALL SPACER AND POWER TAKE-OFF DRIVE GEAR
Install the spacer and power take-off drive gear to the output shaft.




15. INSTALL OUTPUT SHAFT REAR BEARING
Using SST and hammer, drive in the output shaft bearing. SST 09316-60010




16. INSTALL SHIFT FORK SHAFT
(a) Install the high and low shift fork shafts into the shift fork.
(b) Using a pin punch and a hammer, drive in the slotted spring pin.

NOTE: Use a set of soft jaws in the vise to protect the shift fork.




17. INSTALL REAR OUTPUT SHAFT WITH SHIFT FORK AND SHAFT




18. STICK ON THRUST WASHER
Stick the thrust washer to the transfer rear case with MP grease.

NOTE: Be sure that protruding part of washer fits in the case groove.




19. INSTALL TRANSFER REAR CASE
(a) Place a new gasket on the front case.
(b) Install the rear case.

NOTE: Align the high and low shift lever tip with the shift fork shaft groove.

(c) Apply liquid sealer to the two bolts, and install and torque as shown.
Torque: 650 kg-cm (47 ft-lb, 64 Nm)
(d) Install and torque the other bolts.
Torque: 17 mm 650 kg-cm (47 ft-lb, 64 Nm)
14 mm 400 kg-cm (29 ft-lb, 39 Nm)




20. INSTALL 0-RING AND LOCK PLATE
(a) Align the shaft groove to the bolt hole.
(b) Install an 0-ring on the shaft groove.
(c) Using a plastic hammer, drive in the shaft.
(d) Install the lock plate and bolt. Tighten the bolt.
Torque: 130 kg-cm (9 ft-lb, 13 Nm)




21. INSTALL SPEEDOMETER DRIVE GEAR AND SPACER




22. ADJUST REAR OUTPUT SHAFT PRELOAD
(a) Install the rear output shaft rear bearing retainer.

NOTE: Align the bearing retainer rib with the case.




(b) Torque the six bolts.
Torque: 350 kg-cm (25 ft-lb, 34 Nm)
(c) Shift the transfer lever to the "N" position.




(d) Temporarily install the rear companion flange lock nut.
(e) Using a torque meter, measure the rear output shaft preload. (Starting torque)
Preload:
New bearing 15-24.7 kg-cm (13.0-21.4 in-lb, 1.5-2.4 Nm)
Reused bearing 7-12 kg-cm (6.1-10.4 in-lb, 0.7-1.2 Nm)
If the preload is not within specification, remove the outer race of the rear output shaft rear bearing with SST. SST 09514-35011
Reselect an adjusting shim.




NOTE: The preload will change about 10.0 kg-cm (8.7 in-lb, 1.0 Nm) with each shim thickness.




(f) Remove the rear companion flange lock nut.




23. REMOVE REAR OUTPUT SHAFT REAR BEARING RETAINER




24. INSTALL REAR OUTPUT SHAFT REAR BEARING RETAINER
(a) Align the bearing retainer rib with the case rib and install the retainer with a new gasket.
(b) Apply liquid sealer to the six bolts.
(c) Install and torque the bolts.
Torque: 350 kg-cm (25 ft-lb, 34 Nm)




25. INSTALL FRONT AND REAR COMPANION FLANGE
(a) Install the companion flange.
(b) Using SST to hold the companion flange, install the companion flange lock nut. SST 09330-00021
Torque: 1,300kg-cm (94 ft-lb, 127 Nm)
(c) Stake the companion flange lock nut.




26. INSTALL TRANSMISSION OUTPUT SHAFT LOCK NUT
(a) Using SST to hold the rear companion flange, install the transmission output shaft lock nut. SST 09330-00021
Torque: 1,300 kg-cm (94 ft-lb, 127 Nm)
(b) Stake the transmission output shaft lock nut.




27. INSTALL POWER TAKE-OFF COVER
(a) Install the power take-off cover with a new gasket to the transfer rear case.
(b) Apply liquid sealer to the two bolts, and install and torque as shown.
Torque: 170 kg-cm (12 ft-lb, 17 Nm)
(c) Install and torque the other bolts.
Torque: 195 kg-cm (14 ft-lb, 19 Nm)




28. INSTALL TRANSFER CASE COVER NO.2
(a) Install the transfer case cover No.2 with a new gasket to the transfer rear case.

NOTE: Face the gasket notch downward.

(b) Apply liquid sealer to the six bolts.
(c) Install and torque the bolts.
Torque: 155kg-cm (lift-lb, 15 Nm)




29. INSTALL SPEEDOMETER DRIVEN GEAR
Torque: 130 kg-cm (9 ft-lb, 13 Nm)




30. INSTALL PLUG, SPRING AND LOCKING BALL
[Mechanical Shift Type]
Apply liquid sealer to the plugs and install the locking balls, springs and plugs.
Torque: 450 kg-cm (33 ft-lb, 44 Nm)
[Electrical Shift Type]
Apply liquid sealer to the plug and install the locking ball, spring and plug.
Torque: 450 kg-cm (33 ft-lb, 44 Nm)




31. INSTALL L4 POSITION SWITCH
[ELECTRICAL SHIFT TYPE]
Torque: 450 kg-cm (33 ft-lb, 44 Nm)




32. INSTALL 4WD INDICATOR SWITCH
Using SST, install the 4WD indicator switch. SST 09817-16011
Torque: 450 kg-cm (33 ft-lb, 44 Nm)




33. INSTALL DUST BOOT




34. INSTALL TRANSFER FRONT DRIVE SHIFT LEVER (MECHANICAL SHIFT TYPE)
35. INSTALL DIAPHRAGM CYLINDER (ELECTRICAL SHIFT TYPE)
(See Diaphragm Cylinder)