Part 2

Overhaul Continued





68. 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)





69. 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 inch)
Maximum clearance: 0.25 mm (0.0098 inch)
If the clearance exceeds the maximum, replace the drive sprocket sub-assembly.





70. 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.





71. 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.
c. Using a snap ring expander, install the new snap ring.





72. 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.





73. 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 Nm (190 kgf-cm, 14 ft. lbs.)





74. 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 inch)





75. 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 inch) or less axial play.
c. Using a snap ring expander, install the new input bearing shaft snap ring.





76. INSTALL TRANSFER INPUT SHAFT SEAL RING NO.1
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.





77. INSTALL TRANSFER LOW PLANETARY GEAR BEARING

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

78. INSTALL TRANSFER THRUST BEARING RACE NO.1
79. INSTALL TRANSFER INPUT SHAFT





80. INSTALL MANUAL TRANSFER PLANETARY CARRIER WASHER
81. INSTALL TRANSFER INPUT GEAR STOPPER BALL
82. INSTALL TRANSFER INPUT GEAR STOPPER





83. 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 inch) axial play.





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





84. 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.





85. INSTALL TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING





86. 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.





87. INSTALL LOW PLANETARY GEAR ASSY W/ INPUT SHAFT SUB-ASSY
a. Install the low planetary gear assy 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.
88. INSTALL TRANSFER OIL PUMP GEAR





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





90. INSTALL TRANSFER OIL PUMP BODY SUB-ASSY
a. Install the oil pump body sub-assembly with the 3 bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
91. INSTALL TRANSFER CASE MAGNET





92. INSTALL TRANSFER OIL SEPARATOR SUB-ASSY
a. Install the oil separator sub-assembly with the 3 bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 in. ft. lbs.)
93. INSTALL TRANSFER CASE PLUG
a. Install the case plug No.1 (filler plug) and a new gasket.
Torque: 37 Nm (377 kgf-cm, 27 ft. lbs.)
94. INSTALL TRANSFER CASE PLUG
a. Install the case plug (drain plug) and a new gasket.
Torque: 37 Nm (377 kgf-cm, 27 ft. lbs.)





95. 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)





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





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





98. INSTALL TRANSFER SHIFT ACTUATOR ASSY
a. Install the shift actuator assy with the 3 bolts.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
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.





99. INSTALL REAR OUT PUT SHAFT ASSY, FRONT DRIVE CHAIN, DRIVEN SPROCKET ASSY, SHIFT FORK NO.1 AND NO.2
a. Install the driven sprocket assy, front drive chain and shift forks No.1 and No.2 onto the rear output shaft assy.

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 assy, front drive chain, driven sprocket assy 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 assy and driven sprocket assy turn smoothly.





100. 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 Nm (194 kgf-cm, 14 ft. lbs.)





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 Nm (190 kgf-cm, 14 ft. lbs.)





101. INSTALL TRANSFER CASE REAR
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 Nm (286 kgf-cm, 21 ft. lbs.)
102. INSTALL TRANSFER SPEEDOMETER DRIVE GEAR
a. Coat the speedometer drive gear ball with MP grease and install it onto the rear output shaft assy.
b. Install the speedometer drive gear.
103. INSTALL TRANSFER OUTPUT WASHER
a. Install the 2 output washers.





104. 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.





105. INSTALL TRANSFER EXTENSION HOUSING SUB-ASSY 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. lbs.)
106. INSTALL SPEEDOMETER DRIVEN GEAR ASSY W/ SENSOR (R155F/RA60F TRANSMISSION)
a. Install the speedometer driven gear w/ sensor with the bolt.
Torque: 11.5 Nm (117 kgf-cm, 8 ft. lbs.)
107. INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSY (A750F TRANSMISSION)
a. Install the speedometer driven hole cover with the bolt.
Torque: 11.5 Nm (117 kgf-cm, 8 ft. lbs.)





108. 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)
109. 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)





110. INSTALL OUTPUT SHAFT COMPANION FLANGE SUB-ASSY
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 (1,203 kgf-cm, 87 ft. lbs.)
c. Using a chisel and hammer, stake the companion flange lock nut.
111. INSTALL OUTPUT SHAFT COMPANION FLANGE SUB-ASSY
a. Using SST, install the companion flange sub-assembly using the same procedure as for the companion flange sub-assembly (rear side).
SST 09330-00021





112. INSTALL TRANSFER RH BEARING RETAINER OIL SEAL (R155F/A750F TRANSMISSION)
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.
113. INSTALL TRANSFER RH BEARING RETAINER OIL SEAL (RA60F TRANSMISSION)





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 inch) for oil seal A
0.5 to 1.0 mm (0.020 to 0.039 inch) 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.





114. INSTALL TRANSFER RH BEARING RETAINER SUB-ASSY
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. lbs.)
115. INSTALL BREATHER OIL DEFLECTOR SUB-ASSY





116. INSTALL TRANSFER CASE COVER SUB-ASSY
a. Install the case cover sub-assembly with the 4 bolts.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)





117. INSTALL TRANSFER ASSY
a. Install the transfer assy with the 8 bolts.

HINT: Take care not to damage the adaptor rear oil seal with the transfer input gear spline.

118. INSTALL MANUAL TRANSMISSION UNIT ASSY (R155F TRANSMISSION)

HINT: Refer to the instructions for the removal of the transmission w/ transfer assy.

119. INSTALL MANUAL TRANSMISSION UNIT ASSY (RA60F TRANSMISSION)

HINT: Refer to the instructions for the removal of the transmission w/ transfer assy.

120. INSTALL AUTOMATIC TRANSMISSION ASSY (A750F TRANSMISSION)

HINT: Refer to the instructions for the removal of the transmission w/ transfer assy.





121. INSTALL TRANSFER CASE LOWER PROTECTOR
a. Install the 4 bolts and the transfer case lower protector.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)
122. ADD TRANSFER OIL
123. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque: 3.9 Nm (40 kgf-cm, 35 in. ft. lbs.)
124. CHECK FOR TRANSFER OIL LEAKAGE
125. CHECK FOR EXHAUST GAS LEAKAGE