Transfer Assembly

TRANSFER ASSEMBLY

1. INSTALL TWO BEARING RACES TO FRONT CASE
(a) Using SST and a hammer, install the center differential bearing race. SST 09316-60010(09316-00010, 09316-00030) 09316-20011

(b) Using SST and a hammer, install the idle gear bearing race. SST 09316-60010(09316-0001 0,09316-00040)

2. INSTALL OIL RECEIVER TO FRONT CASE
(a) Install the oil receiver.
(b) Install and torque the bolt.
Torque: 11.7 Nm (120 kgf-cm, 8.6 ft-lbf)

3. INSTALL SHIFT OUTER LEVER AND INNER LEVER
(a) Install the shift outer lever and inner lever.

(b) Using a pin punch, hammer and socket wrench, install the lever lock pin.

4. ASSEMBLE SHIFT FORK NO.1 AND FORK SHAFT
Using a pin punch and a hammer, drive in the slotted spring pin.

5. INSTALL IDLE GEAR ASSEMBLY, CENTER DIFFERENTIAL ASSEMBLY AND HIGH AND LOW SHIFT FORK ASSEMBLY TO FRONT CASE

6. INSTALL INPUT SHAFT ASSEMBLY
Using a plastic hammer, tap in the input shaft.

7. INSTALL TWO BEARING RACES TO REAR CASE

8. INSTALL OIL STRAINER TO REAR CASE
(a) Install the oil strainer.
(b) Install and torque the bolts.
Torque: 4.9 Nm (50 kgf-cm, 43 in-lbf)

9. ASSEMBLE FRONT CASE AND REAR CASE
(a) Remove any packing material and be careful not to drop oil on the contacting surfaces of the front case.
(b) Apply seal packing to the front case as shown.
Seal packing: Part No.08826 - 00090, THREE BOND 1281 cr equivalent

HINT: Install the rear case as soon as the seal packing is applied.

(d) Apply liquid sealer to the "A" bolt threads.
Sealant: Part No.08833 - 00080, THREE BOND 1344, LOCTITE 242 or equivalent
(e) Install and torque the eight bolts.
Torque: 37 Nm (380 kgf-cm, 27 ft-lbf)

(f) Using snap ring pliers, install the snap ring.

10. INSTALL CASE COVER
(a) Remove any packing material and be careful not to drop oil on the contacting surfaces of the rear case.
(b) Apply seal packing to the rear case as shown.
Seal packing: Part No.08826 - 00090. THREE BOND 1281 or equivalent

HINT: Install the case cover as soon as the seal packing is applied.

(c) Install the case cover.
(d) Apply liquid sealer to the bolt threads.
Sealant: Part No.08833 - 00080, THREE BOND 1344, LOCTITE 242 or equivalent
(e) Install and torque the five bolts.
Torque: 37 Nm (380 kgf-cm. 27 ft-lbf)

11. SELECT ADJUSTING SHIMS FOR IDLER GEAR REAR TAPER ROLLER BEARING
(a) Using a vernier calipers, measure dimension A.

HINT: Lightly hold down the bearing outer race in the thrust direction to eliminate any looseness before making the measurement.

(b) Using a steel straight edge and feeler gauge, measure the clearance of dimension B.
(c) Calculate the required thickness of the adjusting shim.
Thickness: Dimension A + Dimension B + (0.03~0.08 mm)
(d) From the following table, select a shim with a thickness fitting within the range of the calculation in C.

12. (w/o ABS) SELECT ADJUSTING SHIMS FOR OUTPUT SHAFT TAPER ROLLER BEARING
(a) Using a steel straight edge and feeler gauge, measure the clearance of dimension C.

HINT: Lightly hold down the bearing outer race in the thrust direction to eliminate any looseness before making the measurement.

(b) Using a steel straight edge and vernier calipers, measure dimension D.

HINT: Dimension D is the straight edge thickness (Dimension F) subtracted from Dimension E.

Dimension D: Dimension E - Dimension F

(c) Using a steel straight edge and vernier calipers, measure dimension G.

HINT: Dimension G is the straight edge thickness (Dimension F) subtracted from Dimension H.

Dimension G: Dimension H - Dimension F
(d) Calculate the required thickness of the adjusting shim.
Thickness: Dimension G - Dimension D + (0.02 ~ 0.07 mm)

(e) From the following table, select a shim with a thickness fitting within the range of the calculation in (step d).

13. INSTALL ADJUSTING SHIMS TO IDLER GEAR AND OUTPUT SHAFT TAPER ROLLER BEARINGS
(a) Apply MP grease to the adjusting shims.
(b) Install the adjusting shims to bearing outer races.

HINT: Install the thinner shim on the bearing outer race side.

14. (w/ABS) INSTALL RETAINER
Install the retainer with the five bolts.
Torque: 39.2 Nm (400 kgf-cm, 28 ft-lbf)

15. INSTALL REAR EXTENSION HOUSING
(a) Install the oil pump drive shaft.

(b) Remove any packing material and be careful not to drop oil on the contacting surfaces of the rear case.
(c) Apply seal packing to the rear case as shown.
Seal packing: Part No.08826 - 00090 THREE BOND 1281 or equivalent

HINT: Install the rear extension housing as soon as the seal packing is applied.

(d) Install the rear extension housing.
(e) Install and torque the nine bolts.
Torque: 37 Nm (380 kgf-cm, 27 ft-lbf)

16. ASSEMBLE SHIFT FORK NO.2 AND FORK SHAFT
(a) Assemble the shift fork No.2 and fork shaft.
(b) Using a brass bar and hammer. tap in the snap rings.

17. INSTALL CLUTCH SLEEVE, SHIFT FORK NO.2 AND FORK SHAFT

18. INSTALL FRONT EXTENSION HOUSING
(a) Remove any packing material and be careful not to drop oil on the contacting surfaces of the front case.
(b) Apply seal packing to the front case as shown.
Seal packing: Part No.08826 - 00090, THREE BOND 1281 or equivalent

HINT: Install the front extension housing as soon as the seal packing is applied.

(d) Install and torque the six bolts.
Torque: 37 Nm (380 kgf-cm, 27 ft-lbf)

19. INSTALL TRANSFER INDICATOR SWITCHES
Install and torque the Center Diff Lock indicator switch, L 4 position switch and neutral position switch.
Torque: 37 Nm (380 kgf-cm, 27 ft-lbf)

20. INSTALL BALL, SPRING AND SCREW PLUG
(a) Install the ball and spring.

(b) Apply liquid sealer to the screw plug.
Sealant: Part No.08833 - 00080, THREE BOND 1344, LOCTITE 242 or equivalent
(c) Install and torque the screw plug.
(Torx socket wrench T40 09042-00020)
Torque: 19 Nm (190 kgf-cm, 14 ft-lbf)

21. INSTALL OUTPUT GEAR
(a) Apply gear oil to the output gear.
(b) Install the output gear.

NOTICE: Do not turn the output gear.

22. INSTALL MOTOR ACTUATOR
(a) Remove any packing material and be careful not to drop oil on the contacting surfaces of the front case.
(b) Apply seal packing to the front case as shown.
Seal packing: Part No.08826 - 00090, THREE BOND 1281 or equivalent

HINT: Install the motor actuator as soon as the seal packing is applied.

(c) Install the motor actuator.

HINT: Set the motor actuator in differential lock condition.

(d) Install and torque the four bolts.
Torque: 18.1 Nm (185 kgf-cm, 13.3 ft-lbf)

23. INSTALL BREATHER HOSE