With One Touch 2-4 Selector System

DISASSEMBLY
1. Remove speedometer driven gear.
Torque: 11.5 N.m (96 inch lbs.)
2. Remove 4WD-position switch.
Torque: 37 N.m (28 ft. lbs.)
3. Remove plugs of front case.
Torque: 37 N.m (28 ft. lbs.)

INSTALLATION HINT: Check the following items.

^ The input shaft and output shafts rotate smoothly.
^ Shifting can be made smoothly to all position.
4. Remove protector.
Remove the 4 bolts.
Torque: 18 N.m (13 ft. lbs.)





5. Remove front bearing retainer.
a. Remove the 5 bolts.
Torque: 11.5 N.m (96 inch lbs.)





INSTALLATION HINT: Apply liquid sealer to the bolts.
Sealant: THREE BOND 1344, LOCTITE 242 or equivalent.
b. Using a plastic hammer, tap the front bearing retainer and remove it.

INSTALLATION HINT: Remove any Formed In Place Gasket (FIPG) material and be careful not to drop oil on the contacting surfaces of the front bearing retainer. Apply FIPG to the front bearing retainer, as shown.
FIPG, Three Bond 1281 or equivalent.

6. Remove control retainer, gasket and oil deflector.
a. Remove the 4 bolts, control retainer, gasket and oil deflector.
Torque: 18 N.m (13 ft. lbs.)

INSTALLATION HINT: Install a new gasket.





7. Remove front companion flange.
a. Using a chisel and hammer, loosen the staked part of the nut.

INSTALLATION HINT: Stake a new lock nut.

b. Using Special Service Tool (SST) 09330-00021 to hold the flange, remove the companion flange lock nut.
Torque: 118 N.m (87 ft. lbs.)
c. Using SST 09950-40010 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04050, 09957-04010, 09958-04010), remove the companion flange.





8. Remove rear companion flange remove the rear companion flange in the same way as the front companion flange.

INSTALLATION HINT:
^ front companion flange bolts are slim.
^ Rear companion flange bolts are thick.
9. Remove extension housing.
a. Remove the 5 bolts.
Torque: 12 N.m (108 inch lbs.)

INSTALLATION HINT: Apply liquid sealer to the bolts.
Sealant: THREE BOND 1344, LOCTITE 242 or equivalent.

Using a plastic hammer, tap the extension housing and remove it.





INSTALLATION HINT:
Remove any FIPG material and be careful not to drop oil on the contacting surfaces of the extension housing.
^ Apply FIPG to the extension housing, as shown.
FIPG, Three Bond 1281 or equivalent.
10. Remove speedometer drive gear.
a. Remove the speedometer drive gear.

INSTALLATION HINT: Make sure to install the speedometer drive gear in the correct direction.

b. Using a magnetic finger, remove the ball from the rear output shaft.
11. Separate front case and rear case.
a. Remove the 12 bolts.
Torque: 28 N.m (21 ft. lbs.)
b. Using a screwdriver, separate the front case and rear case.





INSTALLATION HINT:
^ Shift the high and low sleeve to low side (rear side) and assemble the front case and rear case. Remove any FIPG material and be careful not to drop oil on the contacting surfaces of the rear case.
^ Apply FIPG to the rear case, as shown.
FIPG, Three Bond 1281 or equivalent.





12. Remove straight screw plug, spring and locking ball.
a. Using a hexagon wrench, remove the screw.
Torque: 18.6 N.m (14 ft. lbs.)

INSTALLATION HINT: Apply liquid sealer to the plugs.
Sealant: THREE BOND 1344, LOCTITE 242 or equivalent.





b. Using a magnetic finger, remove the spring and ball from the both hole.





13. Remove high and low fork shaft, shift fork and shift head No.2
a. Mount the rear case in a vise.

NOTICE: Be careful not to damage the sealing surface.

b. Using a pin punch and hammer, drive out the 2 slotted spring pins.





c. Remove high and low fork shaft, shift fork and shift gear head No.2.

INSTALLATION HINT:
^ Place the high and low shift fork into the groove of the clutch sleeve.
^ Make sure to install the shift fork and shift gear head No.2 in the correct direction.





14. Remove rear output shaft, driven sprocket, chain and front drive shift fork.
a. Remove the shift fork bolt.
Torque: 24 N.m (17 ft. lbs.)





b. Using a snap ring expander, remove the snap ring.





c. Using a plastic hammer, tap the rear case while pulling the rear output shaft, driven sprocket and front drive shift fork.

INSTALLATION HINT:
^ Place the front drive shift fork into the groove of the clutch sleeve.
^ Make sure to install the shift fork in the correct direction.
^ If necessary, heat the rear case to about 50-80°C (122-176°F).

d. Remove the chain.





15. Remove rear output shaft, driven sprocket and chain.
a. Using a snap ring expander, remove the snap ring.





b. Using a plastic hammer, tap the rear case with pulling the rear output shaft and driven sprocket.

INSTALLATION HINT: If necessary, heat the rear case to about 50-80°C (122-176°F).

c. Remove the chain.





16. Remove actuator assembly.
a. Using 2 screwdrivers and a hammer, remove the snap ring.
b. Remove the 3 bolts and the actuator assembly.
Torque: 20 N.m (14 ft. lbs.)





c. Remove the O-ring, 4WD-position switch and snap ring from the actuator assembly.
Torque: 37 N.m (27 ft. lbs.)

INSTALLATION HINT: Coat a new O-ring with gear oil and install it to the actuator assembly.





17. Remove synchronizer ring from input shaft.

INSTALLATION HINT:
^ Apply MP grease to the synchronizer ring.
^ Align the synchronizer ring slots with the shifting keys, and install it on the high and low clutch hub.





18. Remove separator with oil strainer and magnet.
Remove the 3 bolts and the separator with the oil strainer and magnet.
Torque: 7.5 N.m (69 inch lbs.)
19. Remove oil pump body assembly.
Remove the 3 bolts and the oil pump body assembly.
Torque: 7.5 N.m (69 inch lbs.)
20. Remove oil pump drive gear.





21. Remove planetary gear assembly with input shaft.
a. Using a snap ring expander, remove the snap ring.





b. Pull out the planetary gear assembly with the input shaft.

INSTALLATION HINT: If necessary, heat the front case to about 50-80°C (122-176°F).





22. Remove low gear spline piece.
a. Using a screwdriver, remove the snap ring.

INSTALLATION HINT: Be sure the end gap of the snap ring is not aligned with cutout portion of the planetary carrier.





b. Remove the low gear spline piece.





23. Remove needle roller bearing from input shaft.

INSTALLATION HINT: Apply gear oil to the needle roller bearing.





24. Remove input shaft stopper and thrust bearing.
a. Using a snap ring expander, remove the snap ring.

INSTALLATION HINT: Select a snap ring that will allow 0.05 - 0.15 mm (0.0020 - 0.0059 inch) axial play.
Mark: Thickness
A: 2.10 - 2.15 mm (0.0827 - 0.0846 inch)
B: 2.15 - 2.20 mm (0.0846 - 0.0866 inch)
C: 2.20 - 2.25 mm (0.0866 - 0.0886 inch)
D: 2.25 - 2.30 mm (0.0886 - 0.0906 inch)
E: 2.30 - 2.35 mm (0.0906 - 0.0925 inch)
F: 2.35 - 2.40 mm (0.0925 - 0.0945 inch)
G: 2.40 - 2.45 mm (0.0945 - 0.0965 inch)
H: 2.45 - 2.50 mm (0.0965 - 0.0984 inch)
J: 2.50 - 2.55 mm (0.0984 - 0.1004 inch)
K: 2.55 - 2.60 mm (0.1004 - 0.1024 inch)
L: 2.60 - 2.65 mm (0.1024 - 0.1043 inch)
M: 2.65 - 2.70 mm (0.1043 - 0.1063 inch)
N: 2.70 - 2.75 mm (0.1063 - 0.1083 inch)
P: 2.75 - 2.80 mm (0.1083 - 0.1102 inch)
Q: 2.80 - 2.85 mm (0.1102 - 0.1122 inch)
R: 2.85 - 2.90 mm (0.1122 - 0.1142 inch)
S: 2.90 - 2.95 mm (0.1142 - 0.1161 inch)
T: 2.95 - 3.00 mm (0.1161 - 0.1181 inch)
U: 3.00 - 3.05 mm (0.1181 - 0.1201 inch)






b. Remove the input gear stopper, thrust washer and ball.

INSTALLATION HINT: Apply gear oil to the input gear stopper and thrust washer.





25. Remove input shaft, thrust needle roller bearing and thrust race.





26. Remove planetary ring gear.
a. Using a screwdriver, remove the snap ring.

INSTALLATION HINT: Be sure the end gap of the snap ring is not aligned with the upper side of the case.





b. Remove the plug, spring and pin.
Torque: 18.6 N.m (14 ft. lbs.)

INSTALLATION HINT: Apply liquid sealer to the plug.
Sealant: THREE BOND 1344, LOCTITE 242 or equivalent.





c. Remove the planetary ring gear.

INSTALLATION HINT: Make sure to install the ring gear in the correct direction.





27. If necessary, replace speedometer driven gear oil seal.
a. Using SST 09921-00010, remove the oil seal.





b. Coat the lip of oil seal with MP grease.
c. Using SST 09201-10000 (09201-01080), 09950-70010 (09951-07150), drive in a new oil seal.
Drive in depth: 25 mm (0.98 inch)








28. Inspect switches.
Check that there is continuity between terminals as shown.
Switch position: Specified condition.
Pushed: Continuity.
Free: No continuity.
If operation is not as specified, replace the switch.

BASIC SUBASSEMBLY ASSEMBLY

INSTALLATION HINT: Coat all of the sliding and retating surfaces with gear oil before assembly.