Transfer Assembly

TRANSFER ASSEMBLY








1. INSTALL OUTPUT SHAFT TO FRONT CASE
(a) Using a plastic hammer. install the output shaft to the front case.

HINT: Place the front case on something soft such as wooden blocks.

(b) Using a snap ring expander. install the snap ring.




2. INSTALL BEARING RETAINER TO FRONT CASE
(a) Install the bearing retainer with 4 bolts.
(b) Torque the bolts.
Torque: 18 Nm (185 kgf-cm, 13 ft-lbf)




3. INSTALL INPUT GEAR AND COUNTER GEAR TO REDUCTION GEAR CASE
(a) Using a plastic hammer. install the input gear and counter gear to the reduction gear case.

HINT: Place the reduction gear case on something soft such as wooden blocks.

(b) Using a snap ring expander. install the snap ring.




4. INSTALL ROLLER BEARING ON INPUT SHAFT




5. INSTALL NO.2 HUB SLEEVE AND NO.2 SHIFT FORK ON INPUT SHAFT




6. INSTALL REDUCTION GEAR CASE WITH NEW GASKET TO FRONT CASE
(a) Place a new gasket on the front case.
(b) Install the reduction gear case together with the input gear and counter gear.
(c) Install and torque the bolts as shown in the figure.
A Bolt length 47 mm (1.85 in.)
Torque: 37 Nm (380 kgf-cm, 27 ft-lbf)
B Bolt length 49 mm (1.93 in.)
Torque: 37 Nm (380 kgf-cm, 27 ft-lbf)




7. INSTALL FRONT DRIVE GEAR
(a) Using a plastic hammer, install the front drive gear.
(b) Using a snap ring expander, install the snap ring.




8. INSTALL BEARING RETAINER WITH NEW GASKET
(a) Place a new gasket on the front case.
(b) Apply MP grease to the oil seal.
(c) Install the bearing retainer.




(d) Install and torque the bolts.
Torque: 18 Nm (185 kgf-cm, 13 ft-lbf)




9. INSTALL HIGH AND LOW SHIFT FORK SHAFT
(a) Install the high and low shift fork shaft to the No.2 shift fork.




(b) Align the slotted spring hole in the fork with the hole in the shaft.
(c) Using a pin punch and hammer, drive in the slotted spring pin.




10. INSTALL INTERLOCK PIN AND FRONT DRIVE SHIFT FORK SHAFT
(a) Install the interlock pin.
(b) Install the front drive shift fork shaft with the 2 grooves facing outward.




11. INSTALL 2 BALLS, SPRINGS AND PLUGS
(a) Install the ball and spring.




(b) Apply liquid sealer to the plug threads.
Sealant: Part No.08833-00080. THREE BOND 1344, LOCTITE 242 or equivalent
(c) Using a hexagon wrench. install and torque the plug.
Torque: 12 Nm (120 kgf-cm, 9 ft-lbf)
(d) Install the ball, spring and plug to the opposite side.




12. INSTALL LOCKING BALL AND NO.2 SPACER




13. INSTALL NEEDLE ROLLER BEARINGS. TRANSFER LOWER GEAR AND CLUTCH HUB




14. INSTALL NO.1 SHIFT FORK AND HUB SLEEVE
(a) Install the No.1 shift fork together with the hub sleeve to the front drive shift fork shaft.




(b) Align the slotted pin hole in the fork with the hole in the shaft.
(c) Using a pin punch and hammer. install the slotted spring pin.




15. INSTALL OIL PIPES
Install the 2 oil pipes with the cutout side positioned upward.




16. INSTALL IDLER GEAR TO REAR CASE
(a) Using a plastic hammer. install the idler gear to the rear case.

HINT: Place the rear case on something soft such as wooden blocks.

(b) Using a snap ring expander, install the snap ring.




17. INSTALL REAR CASE WITH NEW GASKET
(a) Place a new gasket on the front case.
(b) Install the rear case together with the idler gear.
(c) Install and torque the bolts as shown in the figure.
A Bolt length 47 mm (1.85 in.)
Torque: 39 Nm (400 kgf-cm, 29 ft-lbf)
B Bolt length 112 mm (4.41 in.)
Torque: 37 Nm (380 kgf-cm, 27 ft-lbf)




18. INSTALL BEARING, OIL PUMP SCREW, LOCKING BALL AND SPEEDOMETER DRIVE GEAR




19. INSTALL EXTENSION HOUSING WITH NEW GASKET
(a) Place a new gasket to the rear case.
(b) Apply MP grease to the 2 oil seals.
(c) Install the extension housing with the 7 bolts. Torque the bolts.
Torque: 39 Nm (400 kgf-cm, 21 ft-lbf)




20. INSTALL TRANSFER CASE COVER WITH NEW GASKET
(a) Place a new gasket to the transfer case cover.
(b) Install and torque the 4 bolts.
Torque: 8.8 Nm (90 kgf-cm, 78 in-lbf)




21. INSTALL REAR COMPANION FLANGE
(a) Install the companion flange to the output shaft.
(b) Apply FIPG to the output shaft and companion flange as shown.
FIPG: Part No.08826-00090 THREE BOND 1281 or equivalent




(c) Using SST to hold the flange, install the washer and nut. Torque the nut.
SST 09330-00021
Torque: 123 Nm (1,250 kgf-cm, 90 ft-lbf)
(d) Stake the nut.




22. INSTALL FRONT COMPANION FLANGE
(a) Install the companion flange to the front drive gear.
(b) Using SST to hold the flange, install the washer and nut. Torque the nut.
SST 09330-00021
Torque: 123 Nm (1,250 kgf-cm, 90 ft-lbf)
(c) Stake the nut.
23. INSTALL TRANSFER INDICATOR SWITCH WITH WASHER
Torque: 34 Nm (350 kgf-cm. 25 ft-lbf)
24. INSTALL NO.1 SPEED SENSOR
(a) Install the No.1 speed sensor.
(b) Install and Torque the bolt.
Torque: 11 Nm (115 kgf-cm. 8 ft-lbf)