Part 2

Rear Output Shaft Sub-assembly:

Input Shaft Sub-assembly:

Driven Sprocket Sub-assembly:

Low Planetary Gear Assembly:

TRANSFER ASSEMBLY OVERHAUL





70. REMOVE TRANSFER CASE PLUG
71. REMOVE COMPRESSION SPRING
72. REMOVE PIN
73. 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.
74. INSTALL TRANSFER LOW PLANETARY RING GEAR





a. Install the low planetary ring gear to the front case.

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





b. Using a screwdriver, install the snap ring.





75. INSTALL PIN
76. INSTALL COMPRESSION SPRING
77. INSTALL TRANSFER CASE PLUG
a. Apply sealant to the case plug threads.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
b. Install the case plug.
Torque: 19 Nm (190 kgf-cm, 14 ft. lbs.)





78. INSTALL TRANSFER OUTPUT SHAFT PLATE WASHER
79. INSTALL TRANSFER DRIVE SPROCKET BEARING
80. INSTALL TRANSFER DRIVE SPROCKET SUB-ASSEMBLY
81. INSTALL TRANSFER OUTPUT SHAFT SPACER NO.1
82. 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.





83. INSTALL TRANSFER OUTPUT SHAFT PLATE WASHER
84. INSTALL TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING
85. INSTALL TRANSFER CLUTCH HUB





86. INSTALL CENTER DIFFERENTIAL CASE
87. INSTALL TRANSFER OUTPUT SHAFT SPACER BALL
88. INSTALL TRANSFER OUTPUT SHAFT SPACER NO.2
89. INSTALL TRANSFER LOW PLANETARY RING GEAR HOLE SNAP RING
a. Using a snap ring expander, install the snap ring.
90. INSPECT DRIVE SPROCKET RADIAL CLEARANCE





a. Using a dial indicator, measure the radial clearance of the drive sprocket.
Standard clearance: 0.01 - 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.
91. 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.
92. 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)
93. 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)
94. INSTALL TRANSFER LOW PLANETARY GEAR SPLINE PIECE





a. Using a screwdriver, install the spline piece with the snap ring.
95. INSTALL TRANSFER INPUT BEARING SHAFT SNAP RING





a. Select a snap ring that allows 0.1 mm (0.0039 inch) or less axial play.





b. Using a snap ring expander, install a new snap ring.





96. INSTALL TRANSFER INPUT SHAFT SEAL RING NO.1

HINT:
^ Apply gear oil to the 2 oil seal rings.
^ Engage securely to eliminate clearance as shown in the illustration.





97. INSTALL TRANSFER LOW PLANETARY GEAR BEARING

NOTICE: Make sure to install the transfer low planetary gear bearing in the correct direction.

98. INSTALL TRANSFER THRUST BEARING RACE NO.1
99. INSTALL TRANSFER INPUT SHAFT





100. INSTALL MANUAL TRANSFER PLANETARY CARR WASHER
101. INSTALL TRANSFER INPUT GEAR STOPPER BALL
102. INSTALL TRANSFER INPUT GEAR STOPPER
103. 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.
104. 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. (No.1 )
SST 09310-60011 (09316-00011)
b. Coat the lip of the oil seal with MP grease.





c. Using SST and a hammer, drive in a new oil seal until its surface is flush with the case upper surface. (No 2)
SST 09304-12012
Oil seal drive in depth: -0.5 - 0.5 mm (-0.020 - 0.020 inch)
d. Coat the lip of the oil seal with MP grease.
105. INSTALL LOW PLANETARY GEAR ASSEMBLY W/INPUT SHAFT SUB-ASSEMBLY





a. Install the low planetary gear assembly with input shaft sum assembly.

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





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





106. INSTALL TRANSFER OIL PUMP GEAR
107. INSTALL TRANSFER OIL PUMP BODY O-RING





a. Coat a new O-ring with gear oil and install it to the oil pump body.
108. INSTALL TRANSFER OIL PUMP BODY SUB-ASSEMBLY





a. Install the oil pump body sub-assembly with the 3 bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
109. INSTALL TRANSFER CASE MAGNET
110. INSTALL TRANSFER OIL SEPARATOR SUB-ASSEMBLY





a. Install the oil separator sub-assembly with the 3 bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
111. INSTALL TRANSFER CASE NO.1 PLUG
a. Install the case No.1 plug (filler plug) and a new gasket.
Torque: 37 Nm (377 kgf-cm, 27 ft. lbs.)
112. INSTALL TRANSFER CASE NO.1 PLUG
a. Install the case No.1 plug (drain plug) and a new gasket.
Torque: 97 Nm (377 kgf-cm 97 ft. lbs.)
113. INSTALL TRANSFER SHIFT ACTUATOR ASSEMBLY





a. Install the actuator assembly with the 3 bolts.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
b. Using a screwdriver and hammer, drive in the 2 snap rings.
114. 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)
115. INSTALL TRANSFER DRIVEN SPROCKET BEARING





a. Using a press, install a new driven sprocket bearing.
116. INSTALL REAR OUTPUT SHAFT SUB-ASSEMBLY, FRONT DRIVE CHAIN AND DRIVEN SPROCKET SUB-ASSEMBLY





a. Install the rear output shaft sub-assembly and drive sprocket to the front drive chain.





b. Install the rear output shaft sub-assembly, front drive chain and driven sprocket sub-assembly to the case rear.

HINT: Check that the rear output shaft sub-assembly and driven sprocket sub-assembly turn lightly.

If necessary, that the rear case about 50 - 80°C (122 - 176°F).





c. Using a snap ring expander, install the snap ring.
117. INSTALL CTR DIFFERENTIAL LOCK FORK SUB-ASSEMBLY W/FRONT DRIVE CLUTCH SLEEVE





a. Install the CTR differential lock fork sub-assembly and front drive clutch sleeve.
b. Install the bolt.
Torque: 24 Nm (245 kgf-cm, 18 ft. lbs.)
c. Using a screwdriver and hammer, drive in the snap ring.

NOTICE: Make sure to install the fork and clutch sleeve in the correct direction.

118. INSTALL TRANSFER GEAR SHIFT FORK NO.2 W/TRANSFER HIGH AND LOW CLUTCH SLEEVE





a. Install the gear shift fork No.2 and high and low shift fork shaft and high and low clutch sleeve.

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

b. Apply sealant to the plug No.1 threads.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
c. Install the spring and ball to the hole.
d. Install the plug No.1 to the hole.
Torque: 19 Nm (190 kgf-cm, 14 ft. lbs.)
e. Using a pin punch and hammer, Install the slotted pin.





119. INSTALL TRANSFER OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING
120. INSTALL TRANSFER OUTPUT SHAFT SPACER
121. INSTALL TRANSFER CASE REAR





a. Apply FIPG to the case rear, as shown.
FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent





b. Install the 2 clamps and case rear with the 12 bolts.
Torque: 28 Nm (285 kgf-cm, 21 ft. lbs.)
122. INSTALL TRANSFER OUTPUT WASHER





a. Install the caller and 2 output washers.
123. INSTALL TRANSFER EXTENSION HOUSING TYPE T OIL SEAL





a. Using SST and a hammer, drive in a new oil seal until its surface is flush with the housing upper surface.
SST 09223-06011, 09631-32020
b. Coat the lip of the oil seal with MP grease.
124. INSTALL EXTENSION HOUSING ASSEMBLY





a. Apply FIPG to the extension housing assembly rear, as shown.
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 assembly with the 5 bolts.
Torque: 12 Nm (122 kgf-cm, 9 ft. lbs.)
125. INSTALL TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL





a. Using SST and a hammer, drive in a new oil seal (front).
SST 09950-60010 (09951-00320), 09950-70010 (09951-07100)
b. Coat the lip of the oil seal with MP grease.
126. INSTALL TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL
a. Drive in a new oil seal (rear) in the same way as the oil seal (front).
SST 09950-60010 (09951-00320), 09950-70010 (09951-07100)
b. Coat the lip of the oil seal with MP grease.
127. INSTALL OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY





a. Install the companion flange sub-assembly to the drive sprocket sub-assembly. (front)
b. Using SST to hold the companion flange, install a new companion flange lock nut.
SST 09330-00021
Torque: 118 Nm (1,200 kgf-cm, 87 ft. lbs.)
c. Using a chisel and hammer, stake the companion flange lock nut.
128. INSTALL OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY
a. Using SST, install the companion flange sub-assembly (rear) in the same way as the companion flange sub-assembly. (front).
SST 09330-00021
Torque: 118 Nm (1,200 kgf-cm, 87 ft. lbs.)
129. INSTALL BREATHER OIL DEFLECTOR
130. INSTALL TRANSFER CASE COVER SUB-ASSEMBLY





a. Install the case cover sub-assembly with the 4 bolts.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)
131. INSTALL TRANSFER COVER TYPE T OIL SEAL





a. Using SST and a hammer, drive in a new oil seal until its surface is flush with the retainer upper surface.
b. Coat the lip of the oil seal with MP grease.
SST 09950-60010 (09951-00590), 09950-70010 (09951-07100)
132. INSTALL TRANSFER RH BEARING RETAINER SUB-ASSEMBLY





a. Apply FIPG to the bearing retainer sub-assembly, as shown.
FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent
b. Apply sealant to the bolt thread.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent





c. Install the bearing retainer sub-assembly with the 5 bolts.
Torque: 12 Nm (117 kgf-cm, 8 ft. lbs.)
133. INSTALL TRANSFER GEAR SHIFT HEAD NO.2





a. Using a pin punch and hammer, install the slotted pin to the gear shift head No.2.
134. INSTALL SWITCH





a. Install a new gaskets, the indicator switches and the case No.1 plug.
Torque: 37 Nm (377 kgf-cm, 27 ft. lbs.)





135. INSTALL HOSES

NOTICE:
^ Place the hose that passes between the transfer rear case and the actuator motor.
^ Adjust the clamp position to prevent the excessive bent or expansion/contraction of the hose.

136. INSTALL TRANSFER ASSEMBLY
a. Install the transfer to the automatic transmission.
b. Install the 2 clamps and 8 bolts.
Torque: 24 Nm (245 kgf-cm, 17 ft. lbs.)
137. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY
138. INSTALL TRANSFER CASE LOWER PROTECTOR
a. Install the 4 bolts with the transfer case lower protector.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)
139. ADD TRANSFER OIL