Reassembly

TRANSFER ASSEMBLY

REASSEMBLY

1. INSTALL FRONT DRIVE CLUTCH SLEEVE
(a) Install the drive clutch sleeve onto the rear output shaft.

NOTICE: Make sure that the clutch sleeve is installed facing in the correct direction.

(b) Install the 3 synchromesh shifting keys No. 1 and the 2 synchromesh shifting keys spring No. 1.

NOTICE: Install the key springs so that their end gaps are not in line.

2. INSTALL TRANSFER SYNCHRONIZER RING SET
(a) Install the synchronizer outer ring onto the rear output shaft.

NOTICE: Align the slots of the synchronizer outer ring with the shifting keys.

(b) Install the synchronizer center and the inner rings onto the rear output shaft.

NOTICE: Align the slots of the synchronizer outer with those of the inner rings.

3. INSTALL TRANSFER DRIVE SPROCKET SUBASSEMBLY
(a) Install a new drive sprocket bearing.
(b) Install the drive sprocket sub-assembly.

NOTICE: Align the holes in the drive sprocket with the protrusions on the synchronizer center ring.

(c) Install the output shaft spacer aligned it with the output shaft spacer ball.

4. INSTALL TRANSFER OUTPUT SHAFT REAR RADIAL BALL BEARING
(a) Using SST and a press, install a new output shaft rear radial ball bearing with the output shaft snap ring groove toward the rear.
SST 09316-60011 (09316-00011, 09316-00071)

5. INSPECT DRIVE SPROCKET THRUST CLEARANCE
(a) Using a feeler gauge, measure the drive sprocket thrust clearance.
Standard clearance:
0.10 to 0.25 mm (0.0039 to 0.0098 in.)
Maximum clearance:
0.25 mm (0.0098 in.)
If the clearance exceeds the maximum, replace the drive sprocket sub-assembly.

6. INSTALL TRANSFER HIGH AND LOW CLUTCH SLEEVE
(a) Install the high and low clutch sleeve onto the transfer clutch hub.

NOTICE: Make sure that the high and low clutch hub is installed facing in the correct direction.

7. INSTALL TRANSFER CLUTCH HUB
(a) Using a press, install the transfer clutch hub.

(b) Select an output shaft snap ring that allows the minimum axial play.

8. INSTALL TRANSFER LOW PLANETARY RING GEAR
(a) Install the low planetary ring gear onto the transfer case front.

NOTICE: Be sure to install the low planetary ring gear facing in the correct direction.

(b) Using a screwdriver, install the hole snap ring.

9. INSTALL TRANSFER CASE PLUG
(a) Install the pin and spring.
(b) Apply sealant to the case plug threads.
Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
(c) Install the case plug.
Torque: 18.6 N*m (190 kgf*cm, 14 ft.*lbf)

10. INSTALL TRANSFER LOW PLANETARY GEAR BEARING
(a) Using SST and a press, tap in a new low planetary gear bearing.
SST 09950-60010 (09951-00570), 09950-70010 (09951-07100)
Press in depth:
7.7 to 8.3 mm (0.303 to 0.327 in.)

11. INSTALL TRANSFER INPUT SHAFT BEARING
(a) Using SST and a press, install a new input shaft bearing with the groove facing forward.
SST 09223-15020, 09515-30010, 09950-70010 (09951-07100)

(b) Select a snap ring that allows 0.1 mm (0.004 in.) or less axial play.

12. INSTALL TRANSFER NO. 1 INPUT SHAFT SEAL RING
(a) Apply gear oil to the 2 input shaft seal ring No. 1.
(b) Engage the rings securely to eliminate any clearance, as shown in the illustration.

13. INSTALL TRANSFER LOW PLANETARY GEAR BEARING

NOTICE: Be sure to install the transfer low planetary gear facing in the correct direction.

14. INSTALL TRANSFER NO. 1 THRUST BEARING RACE
15. INSTALL TRANSFER INPUT SHAFT

16. INSTALL MANUAL TRANSFER PLANETARY CARRIER WASHER
17. INSTALL TRANSFER INPUT GEAR STOPPER BALL
18. INSTALL TRANSFER INPUT GEAR STOPPER

19. INSTALL TRANSFER INPUT GEAR STOPPER SHAFT SNAP RING
(a) Select an input gear stopper shaft snap ring that allows 0.05 to 0.15 mm (0.0020 to 0.0059 in.) axial play.

(b) Using a snap ring expander, install the new input gear stopper shaft snap ring.

20. INSTALL TRANSFER CASE OIL SEAL
(a) Using SST and a hammer, tap in a new oil seal until its surface is flush with the case upper surface.
SST 09316-60011 (09316-00011)
(b) Coat the lip of the oil seal with MP grease.

21. INSTALL TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING

22. INSTALL TRANSFER LOW PLANETARY GEAR SPLINE PIECE
(a) Install the low planetary gear spline piece.

(b) Using a screwdriver, install the low planetary gear shaft snap ring.

NOTICE: Make sure that the end gap of the snap ring is not aligned with the cutout of the planetary carrier.

23. INSTALL LOW PLANETARY GEAR ASSEMBLY WITH INPUT SHAFT SUB-ASSEMBLY
(a) Install the low planetary gear assembly w/input shaft sub-assembly.

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

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

24. INSTALL TRANSFER OIL PUMP GEAR

25. INSTALL TRANSFER OIL PUMP BODY O-RING
(a) Coat a new O-ring with gear oil and install it onto the oil pump body.

26. INSTALL TRANSFER OIL PUMP BODY SUBASSEMBLY
(a) Install the oil pump body sub-assembly with the 3 bolts.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)

27. INSTALL TRANSFER CASE MAGNET

28. INSTALL TRANSFER OIL SEPARATOR SUBASSEMBLY
(a) Install the oil separator sub-assembly with the 3 bolts.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)

29. INSTALL TRANSFER CASE PLUG
(a) Install the case plug No. 1 (filler plug) and a new gasket.
Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf)

30. INSTALL TRANSFER CASE PLUG
(a) Install the case plug (drain plug) and a new gasket. Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf)

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

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

33. INSTALL TRANSFER INDICATOR SWITCH NO.1
(a) Coat a new O-ring with gear oil and install it onto the shift actuator assembly.
(b) Install 2 new gaskets and the 2 indicator switches No. 1 onto the shift actuator assembly.
Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf)

34. INSTALL TRANSFER SHIFT ACTUATOR ASSEMBLY
(a) Install the shift actuator assembly with the 3 bolts.
Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
(b) Using a screwdriver and hammer, tap in the shift fork shaft snap ring.

HINT: Install only the snap ring on the rear side of the shaft.

35. INSTALL REAR OUTPUT SHAFT ASSEMBLY, FRONT DRIVE CHAIN, DRIVEN SPROCKET ASSEMBLY, SHIFT FORK NO. 1 AND NO. 2
(a) Install the driven sprocket assembly, front drive chain and shift forks No. 1 and No. 2 onto the rear output shaft assembly.

NOTICE: Make sure that the shift forks No. 1 and No. 2 are installed facing in the correct direction.

(b) Fix the case rear in a vise.
(c) Install the rear output shaft assembly, front drive chain, driven sprocket assembly and shift forks No. 1 and No. 2 onto the case rear.

NOTICE: Do not let the clutch sleeve or shifting key drop.

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

(d) Using a snap ring expander, install the output shaft snap ring.

(e) Using a screwdriver and hammer, tap in the shift fork shaft snap ring.

HINT: Check that the rear output shaft assembly and driven sprocket assembly turn smoothly.

36. INSTALL TRANSFER FRONT DRIVE SHIFT FORK SHAFT
(a) Using a magnetic finger, install the 2 shift inter lock pins onto the shift forks No. 1 and No. 2.

(b) To push in the shift fork shaft, shift the shift fork No. 1 and No. 2 to the positions shown in the illustration.
(c) Push in the shift fork shaft.

NOTICE: Make sure that the shift fork shaft is installed facing in the correct direction.

(d) Install the shift shaft stopper with the bolt.
Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf)

(e) Using a screwdriver and hammer, tap the 2 shift fork shaft snap rings into the shift fork shaft.

(f) Install the 2 shift detent balls and 2 compression springs onto the shift forks No. 1 and No. 2.
(g) Apply sealant to the shift detent ball spring plug threads.
Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
(h) Using a hexagon wrench (6 mm), install the 2 shift detent ball spring plugs onto the shift forks No. 1 and No. 2.
Torque: 18.6 N*m (190 kgf*cm, 14 ft.*lbf)

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

(b) Engage the 2 brackets and install the case rear with the 12 bolts.
Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf)

38. INSTALL TRANSFER SPEEDOMETER DRIVE GEAR
(a) Coat the speedometer drive gear ball with MP grease and install it onto the rear output shaft assembly.
(b) Install the speedometer drive gear.

39. INSTALL TRANSFER OUTPUT WASHER
(a) Install the 2 output washers.

40. INSTALL TRANSFER EXTENSION HOUSING TYPE T OIL SEAL
(a) Using SST and a hammer, tap in a new extension housing type T oil seal until its surface is flush with the housing upper surface.
SST 09554-22010
(b) Coat the lip of the oil seal with MP grease.

41. INSTALL TRANSFER EXTENSION HOUSING SUBASSEMBLY FRONT
(a) Apply FIPG to the extension housing sub-assembly, as shown in the illustration.
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-assembly with the 5 bolts.
Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf)

42. INSTALL SPEEDOMETER DRIVEN GEAR ASSEMBLY WITH SENSOR (for R155F/RA60F)
(a) Install the speedometer driven gear w/sensor with the bolt.
Torque: 11.5 N*m (117 kgf*cm, 8 ft.*lbf)

43. INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY (for A750F)
(a) Install the speedometer driven hole cover with the bolt.
Torque: 11.5 N*m (117 kgf*cm, 8 ft.*lbf)

44. INSTALL TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL
(a) Using SST and a hammer, tap in a new output shaft companion flange oil seal (front side).
SST 09950-60010 (09951-00320), 09950-70010 (09951-07100)

45. INSTALL TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL
(a) Tap in a new output shaft companion flange oil seal using the same procedure as for the oil seal (rear side).
SST 09950-60010 (09951-00320), 09950-70010 (09951-07100)

46. INSTALL OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY
(a) Install the companion flange sub-assembly (front side) onto the drive sprocket sub-assembly.
(b) Using SST to hold the companion flange, install a new companion flange lock nut.
SST 09330-00021
Torque: 118 N*m (1,203 kgf*cm, 87 ft.*lbf)
(c) Using a chisel and hammer, stake the companion flange lock nut.

47. INSTALL OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY
(a) Using SST, install the companion flange subassembly using the same procedure as for the companion flange sub-assembly (rear side). SST 09330-00021

48. INSTALL TRANSFER RH BEARING RETAINER OIL SEAL (for R155F/A750F)
(a) Using SST and a hammer, tap in a new transfer cover type T oil seal until its surface is flush with the retainer upper surface.
SST 09950-60010 (09951-00590), 09950-70010 (09951-07100)
(b) Coat the lip of the oil seal with MP grease.

49. INSTALL TRANSFER RH BEARING RETAINER OIL SEAL (for RA60F)

(a) Using SST and a hammer, tap in 2 new transfer cover type T oil seals A and B as shown in the illustration.
SST 09950-60010 (09951-00580), 09950-70010 (09951-07100)
Drive in depth:
10.5 to 11.5 mm (0.413 to 0.453 in.) for oil seal A
0.5 to 1.0 mm (0.020 to 0.039 in.) for oil seal B
(b) Coat the lip of the oil seal with MP grease.
(c) Install a new O-ring onto the transfer RH bearing retainer.

NOTICE: Apply gear oil to the O-ring when installing the transfer onto the transmission.

50. INSTALL TRANSFER RH BEARING RETAINER SUBASSEMBLY
(a) Apply FIPG to the front bearing retainer subassembly, as shown in the illustration.
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 front bearing retainer sub-assembly with the 5 bolts.
Torque: 11.5 N*m (117 kgf*cm, 8 ft.*lbf)

51. INSTALL BREATHER OIL DEFLECTOR SUBASSEMBLY

52. INSTALL TRANSFER CASE COVER SUB-ASSEMBLY
(a) Install the case cover sub-assembly with the 4 bolts. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)