Part 2

OVERHAUL





71. INSPECT PLANETARY PINION GEAR THRUST CLEARANCE
a) Using a feeler gauge, measure the thrust clearance of the planetary pinion gear.
Standard clearance: 0.11 - 0.84 mm (0.0043 - 0.0331 inch)
Maximum clearance: 0.84 mm (0.0331 inch)
If the clearance exceeds the maximum, replace the planetary gear assembly.





72. INSPECT PLANETARY PINION GEAR RADIAL CLEARANCE
a) Using a dial indicator, measure the radial clearance of the planetary pinion gear.
Standard clearance: 0.009 - 0.038 mm (0.0004 - 0.0015 inch)
Maximum clearance: 0.038 mm (0.0015 inch)
If the clearance exceeds the maximum, replace the planetary gear assembly.





73. REMOVE TRANSFER INPUT SHAFT BEARING
a) Using a snap ring expander, remove the snap ring.
b) Using SST and a press, remove the input shaft bearing.
SST 09554-30011, 09555-55010





74. REMOVE TRANSFER LOW PLANETARY GEAR SPLINE PIECE
a) Using a screwdriver, remove the snap ring.
b) Remove the low planetary gear spline piece.





75. REMOVE TRANSFER LOW PLANETARY GEAR BEARING
a) Using SST, remove the low planetary gear bearing.

NOTICE: Hang SST securely to the clearance between the bearing and low planetary gear.

SST 09612-65014 (09612-01030, 09612-01050)





76. INSPECT DRIVE SPROCKET THRUST CLEARANCE
a) Using a feeler gauge, measure the thrust clearance of the drive sprocket.
Standard clearance: 0.15 - 0.24 mm (0.0059 - 0.0094 inch)
Maximum clearance: 0.24 mm (0.0094 inch)
If the clearance exceeds the maximum, replace the drive sprocket





77. INSPECT DRIVE SPROCKET RADIAL CLEARANCE
a) Using a dial indicator, measure the radial clearance of the drive sprocket
Standard clearance: 0.0 - 0.06 mm (0.0004 - 0.0024 inch)
Maximum clearance: 0.06 mm (0.0024 inch)
If the clearance exceeds the maximum, replace the drive sprocket, output shaft rear or needle roller bearing.





78. REMOVE TRANSFER LOW PLANETARY RING GEAR HOLE SNAP RING
a) Using a snap ring expander, remove the snap ring.
79. REMOVE TRANSFER OUTPUT SHAFT SPACER NO.2
80. REMOVE TRANSFER OUTPUT SHAFT SPACER BALL
81. REMOVE CENTER DIFFERENTIAL CASE





82. REMOVE TRANSFER CLUTCH HUB
83. REMOVE TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING
84. REMOVE TRANSFER OUTPUT SHAFT PLATE WASHER





85. REMOVE TRANSFER SYNCHROMESH SHIFTING KEY SPRING
a) Using a screwdriver, remove the 2 shifting key springs.
86. REMOVE SYNCHROMESH SHIFTING KEY TRANSFER DRIVE
a) Remove the 3 shifting keys.
87. REMOVE FRONT DRIVE CLUTCH SLEEVE





88. REMOVE TRANSFER SYNCHRONIZER RING SET





89. REMOVE TRANSFER OUTPUT SHAFT REAR RADIAL BALL BEARING
a) Using SST and a press, remove the output shaft rear radial ball bearing.
SST 09555-55010





90. REMOVE TRANSFER OUTPUT SHAFT SPACER NO.1
91. REMOVE TRANSFER DRIVE SPROCKET SUB-ASSEMBLY
92. REMOVE TRANSFER DRIVE SPROCKET BEARING
93. REMOVE TRANSFER OUTPUT SHAFT PLATE WASHER





94. INSPECT TRANSFER OUTPUT SHAFT REAR
a) Using a micrometer, measure the outer diameter of the output shaft rear journal surface
Standard diameter:
Part A: 27.98 - 27.99 mm (1.1016 - 1.1020 inch)
Part B: 31.98 - 32.00 mm (1.2591 - 1.2598 inch)
Part C: 34.98 - 35.00 mm (1.3772 - 1.3780 inch)
Part D: 36.98 - 37.00 mm (1.4559 - 1.4567 inch)
Minimum Diameter:
Part A: 27.98 mm (1.1016 inch)
Part B: 31.98 mm (1.2591 inch)
Part C: 34.98 mm (1.3772 inch)
Part D: 36.98 mm (1.4559 inch)
If the outer diameter is less than the minimum, replace the output shaft rear.





95. INSPECT HIGH AND LOW CLUTCH SLEEVE AND GEAR SHIFT FORK NO.2 CLEARANCE
a) Using vernier calipers, measure the thickness of the gear shift fork No.2 claw.
Thickness: 10 mm (0.3937 inch)
b) Using vernier calipers, measure the groove of the high and low clutch sleeve.
Distance: 10.5 mm (0.4134 inch)
c) Calculate a clearance between the high and low clutch sleeve and gear shift fork No.2 clearance.
Standard clearance: 0.26 - 0.84 mm (0.0102 - 0.0331 inch)
Maximum clearance: 0.84 mm (0.0331 inch)
If the clearance exceeds the maximum, replace the high and low clutch sleeve or gear shift fork No.2





96. INSPECT FRONT DRIVE CLUTCH SLEEVE AND GEAR SHIFT FORK NO.1
a) Using vernier calipers, measure the thickness of the gear shift fork No.1 claw.
Thickness: 10 mm (0.3937 inch)
b) Using vernier calipers, measure the groove of the front drive clutch sleeve.
Distance: 10.5 mm (0.4134 inch)
c) Calculate a clearance between the front drive clutch sleeve and gear shift fork No.1.
Standard clearance: 0.26 - 0.84 mm (0.0102 - 0.0331 inch)
Maximum clearance: 0.84 mm (0.0331 inch)
If the clearance exceeds the maximum, replace the front drive clutch sleeve or gear shift fork No.1.





97. INSPECT CENTER DIFFERENTIAL CASE AND HIGH AND LOW CLUTCH SLEEVE
a) Check that the tip of the spline gear of the front drive clutch sleeve is not worn.
b) Install the front drive clutch sleeve to the center differential case and check that the front drive clutch sleeve moves smoothly.





98. INSPECT CENTER DIFFERENTIAL CASE AND FRONT DRIVE CLUTCH SLEEVE
a) Check that the tip of the spline gear of the front drive clutch sleeve is not worn.
b) Install the front drive clutch sleeve to the center differential case and check that the front drive clutch sleeve moves smoothly.





99. REMOVE TRANSFER CASE PLUG
100. REMOVE SPRING, COMPRESSION
101. REMOVE PIN, W/HEAD





102. REMOVE TRANSFER LOW PLANETARY RING GEAR
a) Using a screwdriver, remove the snap ring.





b) Remove the low planetary ring gear from the front case.
103. 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.





104. INSTALL PIN, W/HEAD
105. INSTALL SPRING, COMPRESSION
106. INSTALL TRANSFER CASE PLUG
Torque: 18.6 Nm (190 kgf-cm, 14 ft. lbs.)





107. INSTALL TRANSFER OUTPUT SHAFT PLATE WASHER
108. INSTALL TRANSFER DRIVE SPROCKET BEARING
109. INSTALL TRANSFER DRIVE SPROCKET SUB-ASSEMBLY
110. INSTALL TRANSFER OUTPUT SHAFT SPACER NO.1





111. 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)

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





112. INSTALL TRANSFER SYNCHRONIZER RING SET





113. INSTALL FRONT DRIVE CLUTCH SLEEVE





114. INSTALL SYNCHROMESH SHIFTING KEY TRANSFER DRIVE
a) Install the 3 shifting keys to the clutch hub.
115. INSTALL TRANSFER SYNCHROMESH SHIFTING KEY SPRING
a) Install the 2 shifting key springs to the clutch hub.

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





116. INSTALL TRANSFER OUTPUT SHAFT PLATE WASHER
117. INSTALL TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING
118. INSTALL TRANSFER CLUTCH HUB





119. INSTALL CENTER DIFFERENTIAL CASE
120. INSTALL TRANSFER OUTPUT SHAFT SPACER BALL
121. INSTALL TRANSFER OUTPUT SHAFT SPACER NO.2
122. INSTALL TRANSFER LOW PLANETARY RING GEAR HOLE SNAP RING
a) Using a snap ring expander, install the snap ring.





123. INSPECT DRIVE SPROCKET RADIAL CLEARANCE (See step 77)





124. INSPECT DRIVE SPROCKET THRUST CLEARANCE (See step 76)





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





126. INSTALL TRANSFER LOW PLANETARY GEAR SPLINE PIECE
a) Using a screwdriver, install the spline piece and low planetary gear with the snap ring.





127. INSTALL TRANSFER LOW PLANETARY GEAR BEARING
a) Using SST and a press, drive in a new bearing.
SST 09950-60010 (09951-00570), 09950-70010 (09951-07100)
Bearing press in depth: 7.7 - 8.3 mm (0.303 - 0.327 inch)





128. 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.





129. INSTALL TRANSFER INPUT SHAFT SEAL RING NO.1

HINT: Apply gear oil to the oil seal ring. Engage securely to eliminate clearance as shown in the illustration





130. INSTALL TRANSFER LOW PLANETARY GEAR BEARING
131. INSTALL TRANSFER THRUST BEARING RACE NO.1
132. INSTALL SHAFT, TRANSFER INPUT





133. INSTALL MANUAL TRANSFER PLANETARY CARR WASHER
134. INSTALL TRANSFER INPUT GEAR STOPPER BALL
135. INSTALL TRANSFER INPUT GEAR STOPPER





136. INSTALL TRANSFER INPUT GEAR STOPPER SHAFT SNAP RING





a) Select a input gear stopper snap ring that allows 0.05 - 0.15 mm (0.0020 - 0.0059 inch) axial play.
b) Using a snap ring expander, install a new input gear stopper snap ring.





137. INSTALL TRANSFER CASE OIL SEAL
a) Using SST and a hammer, drive 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.





138. INSTALL LOW PLANETARY GEAR ASSEMBLY W/INPUT SHAFT SUB-ASSEMBLY
a) Install the low planetary gear assembly and input shaft sub-assembly.





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





139. INSTALL TRANSFER OIL PUMP GEAR





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