Part 3

OVERHAUL





141. INSTALL TRANSFER OIL PUMP BODY SUB-ASSY
a) Install the oil pump body sub-assy with the 3 bolts.
Torque: 7.5 Nm (80 kgf-cm, 69 inch lbs.)





142. INSTALL TRANSFER CASE MAGNET
143. INSTALL TRANSFER OIL SEPARATOR SUB-ASSY
a) Install the oil separator sub-assy with the 3 bolts.
Torque: 7.5 Nm (80 kgf-cm, 69 inch lbs.)
144. INSTALL TRANSFER CASE NO.1 PLUG
a) Install the case No.1 plug (filler plug) and a new gasket.
Torque: 37 Nm (380 kgf-cm, 27 ft. lbs.)
145. INSTALL TRANSFER CASE NO.1 PLUG
a) Install the case No.1 plug (drain plug) and a new gasket.
Torque: 37 Nm (380 kgf-cm, 27 ft. lbs.)





146. INSTALL TRANSFER SHIFT ACTUATOR ASSY
a) Install the actuator assy with the 3 bolts.
Torque: 20 Nm (200 kgf-cm, 14 ft. lbs.)
b) Using a screwdriver and hammer, drive in the snap ring.





147. INSTALL TRANSFER INPUT GEAR RADIAL BALL BEARING
a) Using SST and a press, install a new input gear radial bail bearing.
SST 09316-60011 (09316-00031)





148. INSTALL TRANSFER DRIVEN SPROCKET BEARING
a) Using a press, install a new driven sprocket bearing.





149. INSTALL NO.2 STOPPER TRANSFER SHIFT SHAFT





150. INSTALL REAR OUTPUT SHAFT SUB-ASSY, GEAR SHIFT FORK NO.1, FRONT DRIVE CLUTCH SLEEVE, FRONT DRIVE CHAIN AND DRIVEN SPROCKET
a) Install the rear output shaft sub-assy, gear shift fork No.1 and drive sprocket to the front drive chain.





b) Install the rear output shaft sub-assy, gear shift fork No. 1, front drive clutch sleeve, front drive chain and driven sprocket sub-assy to the case rear.

HINT: Check that the rear output shaft sub-assy and driven sprocket sub-assy turn lightly.





c) Using a snap ring expander, install the snap ring.





d) Using a screwdriver and hammer, drive in the snap ring.





e) Using a screwdriver and hammer, drive in the snap ring.





151. INSTALL NO.2 STOPPER TRANSFER SHIFT SHAFT
152. INSTALL ROLLER SHIFT INTER-LOCK PIN





153. INSTALL TRANSFER FRONT DRIVE SHIFT FORK SHAFT
a) Turn the front drive shift fork shaft, and install it on the rear case aligning the cut out position and the inter-lock pin position.
154. INSTALL TRANSFER SHIFT SHAFT STOPPER
a) Install the shift shaft stopper with the bolt
Torque: 19 Nm (195 kgf-cm, 14 ft. lbs.)





155. INSTALL TRANSFER GEAR SHIFT FORK NO.2 W/TRANSFER HIGH AND LOW CLUTCH SLEEVE
a) Install the gear shift fork No.2 and high and low clutch sleeve Install the bolt.
Torque: 24 Nm (245 kgf-cm, 18 ft. lbs.)
156. INSTALL TRANSFER OUTPUT SHAFT SPACER
157. INSTALL TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING





158. INSTALL TRANSFER CASE REAR
a) Apply FIPG to the case rear, as shown
FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent





b) Install the clamp and case rear with the 12 bolts
Torque: 28 Nm (285 kgf-cm, 21 ft. lbs.)





159. INSTALL COLLAR
160. INSTALL TRANSFER OUTPUT WASHER





161. INSTALL OIL (TRANSFER EXTENSION HOUSING SUB-ASSY REAR) SEAL
a) Using SST and a hammer, drive in a new oil seal until its surface is flush with the housing upper surface.
SST 09223-46011, 09631-32020
b) Coat the lip of the oil seal with MP grease.





162. INSTALL TRANSFER EXTENSION HOUSING SUB-ASSY REAR
a) Apply FIPG to the extension housing sub-assy rear, as shown.
FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent
b) Apply sealant to the bolt threads.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent





c) Install the extension housing sub-assy rear with the bolts.
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)





163. INSTALL TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL
a) Using SST and a hammer, drive in a new oil seal (front).
SST 09950-60010 (09951-00320), 09950-70010 (09951-07100)
b) Coat the lip of the oil seal with MP grease.
164. INSTALL TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL
a) Drive in a new oil seal (rear) in the same way as the oil seal (front).
SST 09950-60010 (09951-00320), 09950-70010 (09951-07100)





165. INSTALL OUTPUT SHAFT COMPANION FLANGE SUB-ASSY
a) Install the companion flange sub-assy (front) to the drive sprocket sub-assy.
b) Using SST to hold the companion flange, install a new companion flange lock nut.
Torque: 118 Nm (1,200 kgf-cm, 87 ft. lbs.)
c) Using a chisel and hammer, stake the companion flange lock nut.
SST 09330-00021
166. INSTALL OUTPUT SHAFT COMPANION FLANGE SUB-ASSY
a) Using SST, install the companion flange sub-assy (rear) in the same way as the companion flange sub-assy (front).
Torque: 118 Nm (1,200 kgf-cm, 87 ft. lbs.)
SST 09330-00021





167. INSTALL BREATHER OIL DEFLECTOR
168. INSTALL TRANSFER CASE COVER SUB-ASSY
a) Install the case cover sub-assy with the 4 bolts.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)





169. INSTALL TRANSFER COVER TYPE T OIL SEAL
a) Using SST and a hammer, drive in a new oil seal until its surface is flush with the retainer upper surface.
b) Coat the lip of the oil seal with MP grease.
SST 09950-60010 (09951-00590), 09950-70010 (09951-07100)





170. INSTALL TRANSFER FRONT BEARING RETAINER SUB-ASSY
a) Apply FIPG to the front bearing retainer sub-assy, as shown.
FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent
b) Apply sealant to the bolt thread.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent





c) Install the front bearing retainer embassy with the 5 bolts.
Torque: 11.5 Nm (117 kgf-cm, 8 ft. lbs.)
171. INSTALL HOSE





172. INSTALL TRANSFER ASSY
a) Install the transfer to the automatic transmission.
b) Install the 2 clamps and 8 bolts.
Torque: 24 Nm (240 kgf-cm, 17 ft. lbs.)
173. INSTALL AUTOMATIC TRANSMISSION W/ TRANSFER
174. INSTALL FLYWHEEL HOUSING UNDER COVER
175. INSTALL MANIFOLD STAY NO.2
176. INSTALL MANIFOLD STAY
177. INSTALL STARTER ASSY
178. CONNECT WIRE HARNESS
179. CONNECT CONNECTOR
180. INSTALL FRAME CROSSMEMBER SUB-ASSY NO.3





181. INSTALL TRANSFER CASE LOWER PROTECTOR
a) Install the transfer case lower protector with the 4 bolts.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)
182. INSTALL TRANSMISSION CONTROL CABLE BRACKET NO.1
183. CONNECT TRANSMISSION CONTROL CABLE ASSY
184. INSTALL OIL COOLER INLET TUBE NO.1
SST 09023-12700
185. CONNECT OIL COOLER OUTLET TUBE NO.1
SST 09023-12700
186. INSTALL TRANSMISSION OIL FILLER TUBE SUB-ASSY
187. INSTALL FRONT SUSPENSION MEMBER BRACKET LH
188. INSTALL FRONT SUSPENSION MEMBER BRACKET
189. ADD TRANSFER OIL
190. ADD AUTOMATIC TRANSMISSION FLUID
191. INSPECT AUTOMATIC TRANSMISSION FLUID
192. INSTALL PROPELLER SHAFT ASSY
193. INSTALL PROPELLER SHAFT ASSY FRONT
194. INSTALL EXHAUST PIPE ASSY
195. CONNECT OXYGEN SENSOR
196. INSTALL ENGINE UNDER COVER ASSY REAR
197. INSTALL ENGINE UNDER COVER SUB-ASSY NO.1
198. INSPECT AUTOMATIC TRANSMISSION FLUID
199. INSPECT SHIFT LEVER POSITION
200. CHECK FOR EXHAUST GAS LEAKS
201. WARM UP
202. DRIVING TEST