TRANSFER ASSEMBLY > REASSEMBLY

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1. INSTALL TRANSFER DRIVE SPROCKET SUB-ASSEMBLY (A.D.D. manual shift type)


G034490E01

  1. Apply gear oil to the connecting areas of the clutch sleeve and drive sprocket.

  1. Install the clutch sleeve and 3 shifting keys to the drive sprocket with the 2 shifting key springs.

    NOTICE:
    1. Make sure to install the clutch sleeve in the correct direction.
    2. Set the key springs so that their openings do not overlap, as shown in the illustration.
    3. Make sure that the key springs are firmly connected to the shifting keys.
    4. Make sure that the clutch sleeve and drive sprocket move smoothly.

  1. Apply gear oil to the front drive synchronizer ring's taper cone side.



    C111647E01

  1. Install the front drive synchronizer ring.

  1. Apply gear oil to the output shaft and needle roller bearing.

  1. Install the needle roller bearing in the drive sprocket.

  1. Install the drive sprocket (with clutch sleeve).

  1. Install the ball. Install the spacer so that it is aligned with the ball.



2. INSTALL TRANSFER DRIVE SPROCKET SUB-ASSEMBLY (Normal shift type)


C111651E01

  1. Apply gear oil to the connecting areas of the clutch sleeve and drive sprocket.

  1. Install the clutch sleeve to the drive sprocket.

    NOTICE:
    1. Make sure to install the clutch sleeve in the correct direction.
    2. Make sure that the clutch sleeve and drive sprocket move smoothly.



    C111652E01

  1. Apply gear oil to the output shaft and needle roller bearing.

  1. Install the needle roller bearing in the drive sprocket.

  1. Install the drive sprocket (with clutch sleeve).

  1. Install the ball. Install the spacer so that it is aligned with the ball.



3. INSTALL REAR TRANSFER OUTPUT SHAFT RADIAL BALL BEARING

  1. Apply gear oil to the connecting areas of the output shaft and bearing.



    F007997E01

  1. Using SST and a press, press in a new bearing with the outer race snap ring groove toward the rear.

    SST
    09316-60011   (09316-00011, 09316-00071)



4. CHECK TRANSFER DRIVE SPROCKET THRUST CLEARANCE


C111644

  1. Using a feeler gauge, measure the thrust clearance.

    Standard thrust clearance:
    0.10 to 0.25 mm (0.0039 to 0.0098 in.)

    Maximum thrust clearance:
    0.25 mm (0.0098 in.)

    If the thrust clearance is greater than the maximum, replace the drive sprocket.



5. INSTALL TRANSFER HIGH AND LOW CLUTCH SLEEVE (M/T)


G034488E01

  1. Apply gear oil to the connecting areas of the clutch sleeve and clutch hub.

  1. Install the clutch sleeve and 3 shifting keys to the clutch hub with the 2 shifting key springs.

    NOTICE:
    1. Make sure to install the clutch sleeve in the correct direction.
    2. Set the key springs so that their openings do not overlap, as shown in the illustration.
    3. Make sure that the key springs are firmly connected to the shifting key.
    4. Make sure that the clutch sleeve and clutch hub move smoothly.



6. INSTALL TRANSFER HIGH AND LOW CLUTCH SLEEVE (A/T)


G034489E01

  1. Apply gear oil to the connecting areas of the clutch sleeve and clutch hub.

  1. Install the clutch to the clutch hub.

    NOTICE:
    1. Make sure to install the clutch sleeve in the correct direction.
    2. Make sure that the clutch sleeve and clutch hub move smoothly.



7. INSTALL TRANSFER CLUTCH HUB


C111653E01

  1. M/T:
    Apply gear oil to the connecting areas of a new key retainer and the output shaft.

  1. M/T:
    Using SST and a hammer, tap in the key retainer.

    SST
    09316-60011   (09316-00011)

    NOTICE:
    Be careful not to deform or damage the key retainer.

  1. Apply gear oil to the connecting areas of the clutch hub and output shaft.



    C111654

  1. Using a press, press in the clutch hub.



8. INSTALL TRANSFER OUTPUT SHAFT SHAFT SNAP RING


C111655

  1. Select a new snap ring that allows the minimum axial free play.

    Thickness of snap ring:
    Mark
    		Thickness
    K
    		2.00 to 2.05 mm (0.0787 to 0.0807 in.)
    L
    		2.05 to 2.10 mm (0.0807 to 0.0827 in.)
    A
    		2.10 to 2.15 mm (0.0827 to 0.0846 in.)
    B
    		2.15 to 2.20 mm (0.0846 to 0.0866 in.)
    C
    		2.20 to 2.25 mm (0.0866 to 0.0886 in.)
    D
    		2.25 to 2.30 mm (0.0886 to 0.0906 in.)
    E
    		2.30 to 2.35 mm (0.0906 to 0.0925 in.)
    F
    		2.35 to 2.40 mm (0.0925 to 0.0945 in.)
    G
    		2.40 to 2.45 mm (0.0945 to 0.0965 in.)
    H
    		2.45 to 2.65 mm (0.0965 to 0.0984 in.)
    J
    		2.50 to 2.55 mm (0.0984 to 0.1004 in.)

  1. Using a snap ring expander, install the snap ring.

    NOTICE:
    Make sure that the snap ring is firmly installed to the groove.



9. INSTALL TRANSFER LOW PLANETARY RING GEAR


F043457E01

  1. Install the ring gear to the case front.

    NOTICE:
    Make sure to install the ring gear in the correct direction.



    F043456

  1. Using a screwdriver, install the snap ring.

    NOTICE:
    Make sure that the snap ring is firmly installed to the groove.



10. INSTALL PIN


F043455E01


11. INSTALL COMPRESSION SPRING


12. INSTALL TRANSFER CASE PLUG

  1. Apply sealant to the threads of the plug.

    Sealant:
    Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent

  1. Install the plug.

    Torque:
    18.6 N*m{ 190 kgf*cm , 14 ft.*lbf }



13. INSTALL TRANSFER LOW PLANETARY GEAR BEARING


C111656E01

  1. Using SST and a press, press in a new bearing.

    SST
    09950-60010   (09951-00570)
    09950-70010   (09951-00710)

    Bearing depth:
    7.7 to 8.3 mm (0.303 to 0.327 in.)



14. INSTALL TRANSFER INPUT SHAFT BEARING


C111657E01

  1. Using SST and a press, press in a new bearing with the groove facing forward.

    SST
    09223-15020  
    09515-30010  
    09950-70010   (09951-07100)



15. INSTALL TRANSFER INPUT BEARING SHAFT SNAP RING


C111658

  1. Select a new snap ring that allows 0.1 mm (0.004 in.) or less of axial free play.

    Thickness of snap ring:
    Mark
    		Thickness
    1
    		1.45 to 1.50 mm (0.0571 to 0.0591 in.)
    2
    		1.50 to 1.55 mm (o.0591 to 0.0610 in.)
    3
    		1.55 to 1.60 mm (0.0610 to 0.0630 in.)
    4
    		1.60 to 1.65 mm (0.0630 to 0.0650 in.)
    5
    		1.65 to 1.70 mm (0.060 to 0.0669 in.)

  1. Using a snap ring expander, install the snap ring.

    NOTICE:
    Make sure that the snap ring is firmly installed to the groove.



16. INSTALL NO. 1 TRANSFER INPUT SHAFT SEAL RING


C111636

  1. Apply gear oil to the 2 seal rings.

  1. Install the 2 seal rings to the input shaft.

    HINT:
    Engage the seal rings securely to eliminate clearance, as shown in the illustration.



17. INSTALL TRANSFER LOW PLANETARY GEAR BEARING


G034491E01

  1. Install the bearing to the low planetary gear.

    NOTICE:
    Make sure to install the bearing in the correct direction.



18. INSTALL NO. 1 TRANSFER THRUST BEARING RACE

  1. Install the bearing race to the low planetary gear.



19. INSTALL TRANSFER INPUT SHAFT

  1. Apply gear oil to the contact surfaces of the input shaft and low planetary gear.

  1. Install the input shaft to the low planetary gear.



20. INSTALL MANUAL TRANSFER PLANETARY CARRIER WASHER


G034494E02

  1. Apply gear oil to the washer.

  1. Install the washer to the low planetary gear.



21. INSTALL TRANSFER INPUT GEAR STOPPER BALL

  1. Install the ball to the low planetary gear.



22. INSTALL TRANSFER INPUT GEAR STOPPER

  1. Install the stopper to the low planetary gear.



23. INSTALL TRANSFER INPUT GEAR STOPPER SHAFT SNAP RING


F043514

  1. Select a new snap ring that allows 0.05 to 0.15 mm (0.0020 to 0.0059 in.) of axial free play.

    Thickness of snap ring:
    Mark
    		Thickness
    A
    		2.10 to 2.15 mm (0.0827 to 0.0846 in.)
    B
    		2.15 to 2.20 mm (0.0846 to 0.0866 in.)
    C
    		2.20 to 2.25 mm (0.0866 to 0.0886 in.)
    D
    		2.25 to 2.30 mm (0.0886 to 0.0906 in.)
    E
    		2.30 to 2.35 mm (0.0906 to 0.0925 in.)
    F
    		2.35 to 2.40 mm (0.0925 to 0.0945 in.)
    G
    		2.40 to 2.45 mm (0.0945 to 0.0965 in.)
    H
    		2.45 to 2.50 mm (0.0965 to 0.0984 in.)
    J
    		2.50 to 2.55 mm (0.0984 to 0.1004 in.)
    K
    		2.55 to 2.60 mm (0.1004 to 0.1204 in.)
    L
    		2.60 to 2.65 mm (0.1024 to 0.1043 in.)
    M
    		2.65 to 2.70 mm (0.1043 to 0.1063 in.)
    N
    		2.70 to 2.75 mm (0.1063 to 0.1083 in.)
    P
    		2.75 to 2.80 mm (0.1083 to 0.1102 in.)
    Q
    		2.80 to 2.85 mm (0.1102 to 0.1122 in.)
    R
    		2.85 to 2.90 mm (0.1122 to 0.1142 in.)
    S
    		2.90 to 2.95 mm (0.1142 to 0.1161 in.)
    T
    		2.95 to 3.00 mm (0.1161 to 0.1181 in.)
    U
    		3.00 to 3.05 mm (0.1181 to 0.1201 in.)

  1. Using a snap ring expander, install the snap ring.

    NOTICE:
    Make sure that the snap ring is firmly installed to the groove.



24. INSTALL TRANSFER CASE OIL SEAL


F043515E01

  1. Using SST and a hammer, tap in a new oil seal until its surface is flush with the case upper surface (No. 1).

    SST
    09316-60011  

    Oil seal depth:
    -0.5 to 0.5 mm (-0.020 to 0.020 in.)

    NOTICE:
    Be careful not to damage the case front.

  1. Coat the lip of the seal with MP grease.



    C111659E01

  1. Using SST and a hammer, tap in a new oil seal until its surface is flush with the case upper surface (No. 2).

    SST
    09316-60011  

    Oil seal depth:
    -0.5 to 0.5 mm (-0.020 to 0.020 in.)

    NOTICE:
    Be careful not to damage the case front.

  1. Coat the lip of the seal with MP grease.



25. INSTALL FRONT TRANSFER OUTPUT SHAFT NEEDLE ROLLER BEARING


C111633

  1. Apply gear oil to the bearing.

  1. Install the bearing to the low planetary gear.



26. INSTALL TRANSFER LOW PLANETARY GEAR SPLINE PIECE


C111632

  1. Install the gear spline piece to the low planetary gear.



    C111631

  1. Using a screwdriver, install the snap ring.

    NOTICE:
    Be careful not to damage the gear spline piece.



27. INSTALL TRANSFER LOW PLANETARY GEAR ASSEMBLY WITH TRANSFER INPUT SHAFT


C111630

  1. Install the low planetary gear with input shaft.

    HINT:
    If necessary, heat the case front to about 50 to 80°C (122 to 176°F).



    F043449

  1. Using a snap ring expander, install the snap ring.

    NOTICE:
    Make sure that the snap ring is firmly installed to the groove.



28. INSTALL FRONT TRANSFER DRIVE CLUTCH SYNCHRONIZER RING (M/T)


C111629

  1. Apply gear oil to the synchronizer ring's tapered cone side.

  1. Install the synchronizer ring to the low planetary gear.



29. INSTALL TRANSFER OIL PUMP GEAR


F043448

  1. Apply gear oil to the sliding surface of the oil pump gear.

  1. Install the oil pump gear with the nut.



30. INSTALL TRANSFER OIL PUMP BODY O-RING


F043463

  1. Coat a new O-ring with gear oil and install it to the pump body.



31. INSTALL TRANSFER OIL PUMP BODY SUB-ASSEMBLY


F043447E01

  1. Install the oil pump body with the 3 bolts.

    Torque:
    7.5 N*m{ 76 kgf*cm , 66 in.*lbf }



32. INSTALL TRANSFER CASE MAGNET


F043446


33. INSTALL TRANSFER OIL SEPARATOR SUB-ASSEMBLY

  1. Install the oil separator with the 3 bolts.

    Torque:
    7.5 N*m{ 76 kgf*cm , 66 in.*lbf }



34. INSTALL NO. 1 TRANSFER CASE PLUG (FILLER)

  1. Install a new gasket and the filler plug.

    Torque:
    37 N*m{ 377 kgf*cm , 27 ft.*lbf }



35. INSTALL NO. 1 TRANSFER CASE PLUG (DRAIN)

  1. Install a new gasket and the drain plug.

    Torque:
    37 N*m{ 377 kgf*cm , 27 ft.*lbf }



36. INSTALL TRANSFER INPUT GEAR RADIAL BALL BEARING


F043464E01

  1. Apply gear oil to the contact surfaces of the bearing and driven sprocket.

  1. Using SST and a press, press in a new bearing.

    SST
    09316-60011   (09316-00031)

    NOTICE:
    After press-fitting the bearing to the driven sprocket, check that the bearing moves smoothly.



37. INSTALL TRANSFER DRIVEN SPROCKET BEARING


F044041

  1. Apply gear oil to the contact surfaces of the bearing and driven sprocket.

  1. Using a press, press in a new bearing.

    NOTICE:
    After press-fitting the bearing to the driven sprocket, check that the bearing moves smoothly.



38. INSTALL REAR TRANSFER OUTPUT SHAFT, TRANSFER FRONT DRIVE CHAIN AND TRANSFER DRIVEN SPROCKET


C111628E01

  1. Mount the case rear in a vise.

    NOTICE:
    Place aluminum plates on the vise to prevent damage to the case rear.

  1. Install the output shaft and driven sprocket to the front drive chain.

  1. Install the output shaft, front drive chain and driven sprocket to the case rear.

    NOTICE:
    When installing the output shaft, make sure that the installation of the synchronizer ring, sleeve and shifting keys are not affected.

    HINT:
    Check that the output shaft and driven sprocket turn smoothly.

    If necessary, heat the case rear to approximately 50 to 80°C (122 to 176°F).



    C111627

  1. Using a snap ring expander, install the snap ring.

    NOTICE:
    Make sure that the snap ring is firmly installed to the groove.



39. INSTALL TRANSFER HIGH AND LOW SHIFT FORK SHAFT


C111626E01

  1. Apply gear oil to the connecting areas of the shift fork shaft and each part.

  1. Install the shift fork shaft and No. 2 gear shift fork.

    NOTICE:
    Make sure to install the shift fork shaft and No. 2 gear shift fork in the correct direction.

  1. Install the spring and ball to the hole.

  1. Apply sealant to the threads of the plug.

    Sealant:
    Part No. 08833-00083, THREE BOND 1344, LOCTITE 242 or equivalent

  1. Using a hexagon wrench, install the plug.

    Torque:
    18.6 N*m{ 190 kgf*cm , 14 ft.*lbf }



40. INSTALL FRONT TRANSFER DRIVE SHIFT FORK SHAFT


C111625

  1. Apply gear oil to the straight pin.

  1. Install the straight pin to the hole.



    C111624E01

  1. Apply gear oil to the connecting areas of the shift fork shaft and each part.

  1. Install the shift fork shaft, No. 1 gear shift fork, spring and shift shaft stopper.

    NOTICE:
    Make sure to install the shift fork shaft, No. 1 gear shift fork and shift shaft stopper in the correct direction.



    G034534E01

  1. Using a pin punch and hammer, install the 2 slotted pins.

    NOTICE:
    When installing the slotted pins, make sure the pin's groove labeled A is facing in the same direction as the shaft.

  1. Install the spring and ball to the hole.

  1. Apply sealant to the threads of the plug.

    Sealant:
    Part No. 08833-00083, THREE BOND 1344, LOCTITE 242 or equivalent

  1. Using a hexagon wrench, install the plug.

    Torque:
    18.6 N*m{ 190 kgf*cm , 14 ft.*lbf }



41. INSTALL REAR TRANSFER CASE


F043488E01

  1. Apply FIPG to the case rear as shown in the illustration.

    FIPG:
    Part No. 08826-00090, THREE BOND 1281 or equivalent

    NOTICE:
    If the removed case rear will be reused:
    After removing the case rear, be sure to perform the following before reinstalling it: 1) using a knife, cut off any old FIPG on the case rear's contact surface, 2) clean off any remaining old FIPG from the case rear's contact surface, and 3) reapply FIPG to the case rear.



    G039426

  1. Install the clamp and case rear with the 12 bolts.

    Torque:
    28 N*m{ 285 kgf*cm , 21 ft.*lbf }

    NOTICE:
    Tighten the bolts of the case rear within 10 minutes of applying the FIPG. The FIPG will dry very quickly.



42. INSTALL TRANSFER SPEEDOMETER DRIVE GEAR


43. INSTALL TRANSFER OUTPUT WASHER

  1. Install the 2 output washers.



44. INSTALL TRANSFER COVER OIL SEAL


F043516E01

  1. Using SST and a hammer, tap in a new oil seal until its surface is flush with the housing upper surface.

    SST
    09223-46011  
    09631-32020  

    NOTICE:
    Be careful not to damage the extension housing.

  1. Coat the lip of the oil seal with MP grease.



45. INSTALL TRANSFER EXTENSION HOUSING SUB-ASSEMBLY


F043489E01

  1. Apply FIPG to the extension housing as shown in the illustration.

    FIPG:
    Part No. 08826-00090, THREE BOND 1281 or equivalent

    NOTICE:
    If the removed extension housing will be reused:
    After removing the housing, be sure to perform the following before reinstalling it: 1) using a knife, cut off any old FIPG on the housing's contact surface, 2) clean off any remaining old FIPG from the housing's contact surface, and 3) reapply FIPG to the housing.

  1. Apply sealant to the threads of the bolts.

    Sealant:
    Part No. 08833-00080 THREE BOND 1344, LOCTITE 242 or equivalent

  1. Install the extension housing with the 5 bolts.

    Torque:
    12 N*m{ 22 kgf*cm , 9 ft.*lbf }

    NOTICE:
    Tighten the bolts of the extension housing within 10 minutes of applying the FIPG. The FIPG will dry very quickly.



46. INSTALL SPEEDOMETER DRIVEN GEAR SUB-ASSEMBLY


C113234

  1. Install a new O-ring to the driven gear.



    C113235

  1. Install the driven gear to the sensor with the clip.



47. INSTALL VEHICLE SPEED SENSOR


G022561

  1. Install the sensor with the driven gear with the bolt.

    Torque:
    11.5 N*m{ 117 kgf*cm , 8 ft.*lbf }

  1. Connect the sensor connector.



48. INSTALL TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL (FRONT)


F043517E01

  1. Using SST and a hammer, tap in a new oil seal.

    SST
    09950-60010   (09951-00320)
    09950-70010   (09951-07100)

    NOTICE:
    Be careful not to damage the companion flange.



49. INSTALL TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL (REAR)

  1. Using SST and a hammer, tap in a new oil seal (rear) in the same way as the oil seal (front).

    SST
    09950-60010   (09951-00320)
    09950-70010   (09951-07100)

    NOTICE:
    Be careful not to damage the companion flange.



50. INSTALL OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY (FRONT)


F044048E01

  1. Apply gear oil to the connecting areas of the companion flange and driven sprocket.

  1. Install the companion flange to the driven sprocket.

  1. Using SST to hold the companion flange, install a new lock nut.

    SST
    09330-00021  
    09950-40011   (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04051, 09957-04010, 09958-04011)

    Torque:
    118 N*m{ 1,203 kgf*cm , 87 ft.*lbf }



    F050151E01

  1. Using a chisel and hammer, stake the lock nut to the driven sprocket.

    NOTICE:
    1. Thoroughly stake the shaft to the lock nut's groove.
    2. Be careful not to damage parts around the lock nut.
    3. Do not apply excessive force to the shaft.



51. INSTALL OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY (REAR)

  1. Apply gear oil to the connecting areas of the companion flange and output shaft.

  1. Using SST, install the companion flange (rear) in the same way as the companion flange (front).

    SST
    09330-00021  
    09950-40011   (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04051, 09957-04010, 09958-04011)

    Torque:
    118 N*m{ 1,203 kgf*cm , 87 ft.*lbf }



52. INSTALL BREATHER OIL DEFLECTOR SUB-ASSEMBLY


53. INSTALL TRANSFER CONTROL SHIFT LEVER RETAINER SUB-ASSEMBLY (Transfer on type)


C111616

  1. Install the retainer with the 4 bolts.

    Torque:
    18 N*m{ 183 kgf*cm , 13 ft.*lbf }



54. INSTALL TRANSFER CASE COVER SUB-ASSEMBLY (Adapter on type)


C111617

  1. Install the case cover with the 4 bolts.

    Torque:
    18 N*m{ 183 kgf*cm , 13 ft.*lbf }



55. INSTALL TRANSFER COVER OIL SEAL


F043518E01

  1. Using SST and a hammer, tap in a new oil seal until its surface is flush with the bearing retainer upper surface.

    SST
    09950-60010   (09951-00590)
    09950-70010   (09951-07100)

    NOTICE:
    Be careful not to damage the bearing retainer.

  1. Coat the lip of the oil seal with MP grease.



56. INSTALL TRANSFER BEARING RETAINER SUB-ASSEMBLY


F043490E01

  1. Apply FIPG to the bearing retainer as shown in the illustration.

    FIPG:
    Part No. 08826-00090, THREE BOND 1281 or equivalent

    NOTICE:
    If the removed bearing retainer will be reused:
    After removing the retainer, be sure to perform the following before reinstalling it: 1) using a knife, cut off any old FIPG on the retainer's contact surface, 2) clean off any remaining old FIPG from the retainer's contact surface, and 3) reapply FIPG to the retainer.

  1. Apply sealant to the bolt threads.

    Sealant:
    Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent

  1. Install the retainer with the 5 bolts.

    Torque:
    11.5 N*m{ 117 kgf*cm , 8 ft.*lbf }

    NOTICE:
    Tighten the bolts of the bearing retainer within 10 minutes of applying the FIPG. The FIPG will dry very quickly.



57. INSTALL TRANSFER GEAR SHIFT HEAD (Adapter on type)


G034493E01

  1. Install the No. 1 and No. 2 gear shift heads to the front drive shift fork shaft and high and low shift fork shaft.



    F050152E01

  1. Using a pin punch and hammer, tap in the 2 slotted pins to the No. 1 and No. 2 gear shift heads.

    NOTICE:
    When installing the slotted pins, make sure the pin's groove labeled A is facing in the same direction as the shaft.



58. INSTALL TRANSFER INDICATOR SWITCH


C097064E01

  1. Install a new gasket and the indicator switch.

    Torque:
    37 N*m{ 377 kgf*cm , 27 ft.*lbf }

    HINT:
    Indicator switch:
    No. 1
    		Indicator switch (neutral position) for A/T
    No. 2
    		Indicator switch (L4 position) for A/T or M/T w/ ABS
    No. 3
    		Indicator switch (4WD) for A/T and M/T