Component Parts Removal

DISASSEMBLY
1. Remove breather hose.
2. Remove dynamic damper. Remove the two bolts and dynamic damper.

INSTALLATION NOTE: Apply adhesive to the bolt threads.
Adhesive: THREE BOND 1324 or equivalent
Torque: 37 Nm (27 ft. lbs.).

3. Remove motor actuator. Remove the four bolts and motor actuator.

INSTALLATION NOTE:
^ Set the motor actuator in differential lock condition.





^ Apply Formed In Place Gasket (FIPG) to the front case.
FIPG THREE BOND 1281 or equivalent.
Torque: 18 Nm (13 ft. lbs.).

4. Remove output gear from front case.

INSTALLATION NOTE: Apply gear oil to the output gear.

INSTALLATION NOTICE: Do not turn the output gear.





5. Remove screw plug, spring and ball, as follows:
a. Using a torx socket wrench (T40), remove the screw plug.

INSTALLATION NOTE: Apply liquid sealer to the screw plug.
Sealant: THREE BOND 1344, LOCTITE 242 or equivalent.
Torque: 19 Nm (14 ft. lbs.).

b. Using a magnetic finger, remove the spring and ball.
6. Remove transfer indicator switch. Remove the center differential lock indicator switch, L4 position switch, neutral position switch and three gaskets.
Torque: 37 Nm (27 ft. lbs.).





7. Remove front extension housing. Remove the six bolts and front extension housing.

REMOVAL NOTE: If necessary, tap the front extension housing with a plastic hammer.

INSTALLATION NOTE:





^ Set the clutch sleeve in differential lock condition.
^ Apply FIPG to the front case.
FIPG: Part No.08826-00090, THREE BOND 1281 or equivalent
Torque: 37 Nm (27 ft. lbs.).





8. Remove clutch sleeve, shift fork No.2 shaft and shift fork No.2

INSTALLATION NOTE: Make sure to install the clutch sleeve in the correct direction.

9. Separate shift fork No.2 shaft and shift fork No.2, as follows:





a. Using two screwdrivers and a hammer, tap out the 3 snap rings from the shift fork No.2 shaft.
b. Separate the shift fork No.2 shaft and shift fork No.2.





10. Remove rear extension housing. Remove the nine bolts and rear extension housing.

REMOVAL NOTE: If necessary, tap the rear extension housing with a plastic hammer.

INSTALLATION NOTE: Apply FIPG to the rear case.
FIPG: THREE BOND 1281 or equivalent.
Torque: 37 Nm (27 ft. lbs.).

11. Remove retainer from rear case. Remove the five bolts and retainer.
Torque: 39 Nm (28 ft. lbs.).
12. Remove adjusting shim.

INSTALLATION NOTE: Select adjusting shims for the idler gear rear taper roller bearing.





^ Using vernier calipers, measure dimension A.
^ Lightly hold down the bearing outer race in the thrust direction to eliminate any looseness before making the measurement.





^ Using a steel straight edge and feeler gauge, measure the clearance of dimension B. Calculate the required thickness of the adjusting shim.
^ Thickness: Dimension A + Dimension B + (0.022-0.049 mm, 0.0009-0.0019 inch).





^ From the table, select a shim so that it's thickness is within the range of calculation.

INSTALLATION NOTE: Select adjusting shims for the output shaft taper roller bearing.





^ Using a steel straight edge and feeler gauge, measure the clearance of dimension C.
^ Lightly hold down the bearing outer race in the thrust direction to eliminate any looseness before making the measurement.
^ Calculate the required thickness of the adjusting shim.
Thickness: Dimension C + (0.014-0.039 mm, 0.0006-0.0015 inch).





^ From the following table, select a shim so that its thickness in within the range of the calculation.
13. Remove oil strainer from rear case. Remove the two set bolts and oil strainer.
Torque: 4.9 Nm (43 inch lbs.).





14. Remove case cover, as follows:
a. Remove the five bolts.

INSTALLATION NOTE: Apply liquid sealer to the bolt threads.
Sealant: THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 37 Nm (27 ft. lbs.).

b. Using a brass bar and hammer, tap the case cover and remove it.

INSTALLATION NOTE: Apply FIPG to the rear case.
FIPG: THREE BOND 1281 or equivalent.

15. Separate front case and rear case, as follows:
a. Using a snap ring expander, remove the snap ring from the rear case.
b. Remove the eight bolts bolts.





INSTALLATION NOTE: Apply liquid sealer to the "A" bolt threads.
Sealant: THREE BOND 1344, LOCTITE 242 or equivalent.
Torque: 37 Nm (27 ft. lbs.).

c. Using a brass bar and hammer, tap the rear case and separate it.

INSTALLATION NOTE: Apply FIPG to the front case.
FIPG: THREE BOND 1281, or equivalent.





16. Remove two bearing races from rear case.
17. Remove input shaft assembly. Using a plastic hammer, remove the input shaft assembly.





18. Remove idler gear assembly, center differential assembly, shift fork No.1 and shift fork No.1 shaft from front case.
19. Separate shift fork No.1 and shift fork No.1 shaft, as follows:





a. Using a pin punch and a hammer, drive out the slotted spring pin.
b. Separate the shift fork No.1 and shift fork No.1 shaft.
20. Remove shift outer lever and inner lever, as follows:
a. Remove the nut and washer from the shift outer lever.
Torque: 12 Nm (108 inch lbs.).





b. Using a brass bar, hammer and socket wrench, tap out the lever lock pin.
c. Remove the shift outer lever, washer and inner lever from the front case.
21. If necessary, replace shift lever oil seal, as possible.
a. Using a screwdriver, pry out the oil seal.





b. Using Special Service Tool (SST) 09950-70010 (09951-07150) or equivalents, and a hammer, drive in a new oil seal.
22. If necessary, replace input shaft oil seal, as follows:





a. Using SST 09316-60011 (09316-00011) or equivalent, and a hammer, drive out the oil seal.





b. Using SST 09316-60011 (09316-00011, 09316-00031) or equivalent, and a hammer, drive in a new oil seal.
23. Remove oil receiver from front case Remove the bolt and oil receiver.
Torque: 12 Nm (108 inch lbs.).
24. Remove two bearing races from front case, as follows:





a. Using SST 09950-40010, 09950-60010 (09951-00320) or equivalents, remove the bearing race (for idler gear).





INSTALLATION NOTE: Using SST 09316-60011 (09316-00011, 09316-00041) or equivalents, and a hammer, install the bearing race (for idler gear).





b. Using a brass bar and hammer, remove the bearing race (for output shaft).





INSTALLATION NOTE: Using SST 09316-20011, 09316-60011 (09316-00011, 09316-00031) or equivalents, and a hammer, install the bearing race (for output shaft).





25. Inspect transfer indicator switch. Check that there is continuity between the terminals, as shown.
Switch position: Push
Specified: Continuity
Switch position: Free
Specified: No continuity

If continuity is not as specified, replace the switch.

ASSEMBLY
Reassembly is in the reverse order of disassembly.

NOTE: Coat all of the sliding and rotating surfaces with gear oil before assembly.