Reassembly

VF4AM TRANSFER: TRANSFER ASSEMBLY: REASSEMBLY

REASSEMBLY

1. INSTALL TRANSFER LOW PLANETARY RING GEAR
(a) Install the low planetary ring gear to the front case.

(b) Using a screwdriver, install the snap ring.
2. INSTALL WITH HEAD PIN

(a) Install w/ head pin.
3. INSTALL COMPRESSION SPRING
4. INSTALL TRANSFER CASE PLUG
Torque: 18.6 Nm (190 kgf-cm, 14 ft-lbf)
5. INSTALL TRANSFER OUTPUT SHAFT PLATE WASHER

(a) Install the transfer output shaft plate washer.
6. INSTALL TRANSFER DRIVE SPROCKET BEARING
7. INSTALL TRANSFER DRIVE SPROCKET SUB-ASSEMBLY
8. INSTALL NO. 1 TRANSFER OUTPUT SHAFT SPACER
9. INSTALL TRANSFER OUTPUT SHAFT REAR RADIAL BALL BEARING

(a) Using SST and a press, install a new output shaft rear radial ball bearing.
SST: 09316-60011
09316-00011
09316-00071

NOTE: Install the output shaft rear radial ball bearing so that the bearing snap ring groove face to the rear.

10. INSTALL TRANSFER SYNCHRONIZER RING SET

(a) Install the synchronizer ring.
11. INSTALL FRONT DRIVE CLUTCH SLEEVE

(a) Install front drive clutch sleeve.
12. INSTALL SYNCHROMESH SHIFTING KEY TRANSFER DRIVE

(a) Install the3 shifting keys to the clutch hub.
13. INSTALL TRANSFER SYNCHROMESH SHIFTING KEY SPRING
(a) Install the 2 shifting key springs to the clutch hub.

NOTE: Position the shifting key springs so that their end gaps are not aligned.

14. INSTALL TRANSFER OUTPUT SHAFT PLATE WASHER

(a) Install the transfer output shaft plate washer.
15. INSTALL TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING
16. INSTALL TRANSFER CLUTCH HUB
17. INSTALL CENTER DIFFERENTIAL CASE

(a) Install the center differential case.
18. INSTALL TRANSFER OUTPUT SHAFT SPACER BALL
19. INSTALL TRANSFER OUTPUT SHAFT SPACER NO.2
20. INSTALL TRANSFER LOW PLANETARY RING GEAR HOLE SNAP RING
(a) Using a snap ring expender, install the snap ring.
21. INSTALL DRIVE SPROCKET RADIAL CLEARANCE
22. INSPECT DRIVE SPROCKET THRUST CLEARANCE
23. INSTALL TRANSFER INPUT SHAFT BEARING

(a) Using SST and a press, install a new bearing with the groove facing forward.
SST: 09223-15020
SST: 09515-30010
SST: 09950-70010
09951-07100
24. INSTALL TRANSFER LOW PLANETARY GEAR SPLINE PIECE

(a) Using a screwdriver, install the spline piece and low planetary gear with the snap ring.

25. 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
SST: 09950-70010
09951-07100
Press in depth:
7.7 to 8.3 mm (0.303 to 0.327 in.)
26. INSTALL TRANSFER INPUT BEARING SHAFT SNAP RING

(a) Select a snap ring that allows the minimum axial play.

(b) Using a snap ring expander, install a new snap ring.
27. INSTALL TRANSFER NO. 1 INPUT SHAFT SEAL RING

(a) Apply gear oil to the oil seal ring.
(b) Engage securely to eliminate clearance as shown in the illustration.
28. INSTALL TRANSFER LOW PLANETARY GEAR BEARING

(a) Install the transfer low planetary gear bearing.
29. INSTALL NO. 1 TRANSFER THRUST BEARING RACE
30. INSTALL TRANSFER INPUT SHAFT
31. INSTALL MANUAL TRANSFER PLANETARY CARRIER WASHER

(a) Install the manual transfer planetary carrier washer.
32. INSTALL TRANSFER INPUT GEAR STOPPER BALL
33. INSTALL TRANSFER INPUT GEAR STOPPER
34. 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.
35. 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.
36. INSTALL LOW PLANETARY GEAR ASSEMBLY WITH INPUT SHAFT SUB-ASSEMBLY

(a) Install the low planetary gear assembly with input shaft sub-assembly.

(b) Using a snap ring expander, install the shaft snap ring.
37. INSTALL TRANSFER OIL PUMP GEAR

(a) Install transfer oil pump gear.
38. INSTALL TRANSFER OIL PUMP BODY O-RING

(a) Coat a new O-ring with gear oil and install it to the oil pump body.
39. INSTALL TRANSFER OIL PUMP BODY SUB-ASSEMBLY

(a) Install the oil pump body sub-assembly with the 3 bolts.
Torque: 7.8 Nm (80 kgf-cm, 69 in-lbf)
40. INSTALL TRANSFER CASE MAGNET
41. INSTALL TRANSFER OIL SEPARATOR SUB-ASSEMBLY

(a) Install the oil separator sub-assembly with the 3 bolts.
Torque: 7.8 Nm (80 kgf-cm, 69 in-lbf)
42. INSTALL TRANSFER CASE PLUG
(a) Install the case plug No. 1 (filler plug) and a new gasket.
Torque: 37 Nm (380 kgf-cm, 27 ft-lbf)
43. INSTALL TRANSFER CASE PLUG
(a) Install the case plug (drain plug) and a new gasket.
Torque: 37 Nm (380 kgf-cm, 27 ft-lbf)
44. INSTALL TRANSFER SHIFT ACTUATOR ASSEMBLY

(a) Install the shift actuator assembly with the 3 bolts.
Torque: 20 Nm (200 kgf-cm, 14 ft-lbf)
(b) Using a screwdriver and hammer, drive in the snap ring.
45. 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
46. INSTALL TRANSFER DRIVEN SPROCKET BEARING

(a) Using a press, install a new driven sprocket bearing.
47. INSTALL NO.2 STOPPER TRANSFER SHIFT SHAFT

(a) Install No. 2 stopper transfer shift shaft.
48. INSTALL REAR OUTPUT SHAFT SUB-ASSEMBLY, NO. 1 GEAR SHIFT FORK, FRONT DRIVE CLUTCH SLEEVE, FRONT DRIVE CHAIN AND DRIVEN SPROCKET

(a) Install the rear output shaft sub-assembly, gear shift fork No. 1 and drive sprocket to the front drive chain.

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

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

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

(e) Using a screwdriver and hammer, drive in the snap ring.
49. INSTALL NO.2 STOPPER TRANSFER SHIFT SHAFT

(a) Install No. 2 stopper transfer shift shaft.
50. INSTALL OR ROLLER SHIFT INTER-LOCK PIN
51. 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.
52. INSTALL TRANSFER SHIFT SHAFT STOPPER
(a) Install the shift shaft stopper with the bolt.
Torque: 19 Nm (195 kgf-cm, 14 ft-lbf)
53. INSTALL TRANSFER GEAR SHIFT FORK NO. 2 WITH TRANSFER HIGH AND LOW CLUTCH SLEEVE

(a) Install the gear shift fork No. 2 and high and low clutch sleeve.
(b) Install the bolt.
Torque: 24 Nm (245 kgf-cm, 18 ft-lbf)
54. INSTALL TRANSFER OUTPUT SHAFT SPACER
55. INSTALL TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING
56. 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-lbf)
57. INSTALL COLLAR

(a) Install collar.
58. INSTALL TRANSFER OUTPUT SHAFT WASHER
59. INSTALL TRANSFER EXTENSION HOUSING TYPE T OIL 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
SST: 09631-32020
(b) Coat the lip of the oil seal with MP grease.
60. INSTALL TRANSFER EXTENSION HOUSING SUB-ASSEMBLY 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 Nm (122 kgf-cm, 9 ft-lbf)
61. INSTALL TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL

(a) Using SST and a hammer, drive in a new oil seal (front side).
SST: 09950-60010
09951-00320
SST: 09950-70010
09951-07100
(b) Coat the lip of the oil seal with MP grease.
62. INSTALL TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL
(a) Drive in a new output shaft companion flange oil seal using the same procedure as for the oil seal.
SST: 09950-60010
09951-00320
SST: 09950-70010
09951-07100
63. 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 Nm (1,200 kgf-cm, 87 ft-lbf)
(c) Using a chisel and hammer, stake the companion flange lock nut.
64. INSTALL OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY
(a) Using SST, install the companion flange sub-assembly using the same procedure as for the companion flange sub-assembly (rear side).
Torque: 118 Nm (1,200 kgf-cm, 87 ft-lbf)
SST: 09330-00021
65. INSTALL BREATHER OIL DEFLECTOR
66. INSTALL TRANSFER CASE COVER SUB-ASSEMBLY

(a) Install the case cover sub-assembly with the 4 bolts.
Torque: 18 Nm (185 kgf-cm, 13 ft-lbf)
67. 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
SST: 09950-70010
09951-07100
68. INSTALL TRANSFER RH BEARING RETAINER SUB-ASSEMBLY

(a) Apply FIPG to the front bearing retainer 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 front bearing retainer sub-assembly with the 5 bolts.
Torque: 11.5 Nm (117 kgf-cm, 8 ft-lbf)
69. INSTALL HOSES