Assembly of 4WD Change-Over Mechanism
1. INSTALL NEW APPLY GASKET
2. INSTALL REAR VALVE BODY
a. Install the valve body with two gaskets and plate to the transmission.
b. Torque the four bolts.
Torque: 55 kg-cm (48 in.-lb, 5.4 N.m)
3. INSTALL OUTPUT SHAFT
a. Using SST and a press, install the radial ball bearing to the output shaft.
SST 09506-30011
b. Using snap ring pliers, install the snap ring to the output shaft.
c. Install the needle roller bearing and snap ring to the output shaft.
d. Using SST and a plastic hammer, install the output shaft to the extension housing.
SST 09316-60010
4. INSTALL EXTENSION HOUSING NEW OIL SEAL
a. Using SST and a hammer, drive in a new oil seal. (even with the surface of the housing)
SST 09325-12010
b. Apply MP grease to the oil seal lip.
5. INSTALL REAR SERVO PISTON ASSEMBLY
a. Apply ATF (DEXRON (R) II) to the extension housing and piston sliding parts.
b. Align the protruding part of the extension housing in the groove, and assemble the piston to the extension housing. Be careful not to damage the piston oil seal.
c. Install the twelve compression springs to the servo piston.
d. Clean the oil cleaner magnet and install it to the spring seat.
e. Install the spring seat on the rear servo piston.
f. Using SST, push down the spring seat and install the snap ring.
SST 09223-41020
6. CHECK OPERATION OF REAR SERVO PISTON
a. Using compressed air (approx. 2 kg/sq.cm, 28 psi or 196 kPa) confirm that the piston is fully seated against the return spring stopper.
b. Check the piston stroke.
Standard piston stroke: 10 mm (0.39 in.)
7. INSTALL SPEEDOMETER DRIVE GEAR
a. Install the locking ball and speedometer drive gear to the intermediate shaft.
b. Using snap ring pliers, install the snap ring.
8. INSTALL INTERMEDIATE SHAFT
a. Install the intermediate shaft to the transmission.
b. Install the bearing race, bearing and bearing race.
9. INSTALL EXTENSION HOUSING AND GASKET
Torque: 195 kg-cm (14 ft-lb, 19 N.m)
10. INSTALL SPEEDOMETER DRIVEN GEAR
11. INSTALL 4WD CHANGE-OVER SOLENOID