Part 2

OVERHAUL





51. INSTALL TRANSFER RING GEAR MOUNTING CASE
a. Install the transfer ring gear mounting case to the transfer case.

NOTICE: Damage to the splice, the bearing's rotating surface and gear face may cause a decrease in their strength. Care should be taken when installing them.

52. INSTALL TRANSFER RING GEAR MOUNTING CASE WASHER NO.2
a. Install the transfer ring gear mounting case washer No.2 to the transfer RH bearing retainer sub-assembly

HINT: Reuse the washer.





53. INSTALL CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING
a. Using SST(s) and a press, install the center differential case tapered roller bearing RH outer race to the transfer RH bearing retainer sub-assembly.
SST 09950-60010 (09951-00620), 09950-70010 (09951-07150)
54. INSTALL TRANSFER RH BEARING RETAINER SUB-ASSEMBLY





a. Place the transfer the face where the transfer RH bearing retainer sub-assembly is to be installed facing up.
b. Center-align the transfer ring gear mounting case and the transfer case.





c. Insert the SST(s) into the transfer RH bearing retainer sub-assembly.
SST 09387-00090

NOTICE: Insert SST(s) straight in order not to damage the oil seal lip.





d. Insert the transfer RH bearing retainer sub-assembly together with the SST(s) into the transfer case.

NOTICE: Interference between the case and retainer, and between the transfer ring gear mounting case and SST(s) should be carefully avoided.

HINT: If the retainer cannot be inserted, tap it in with a plastic hammer.





e. After inserting the transfer RH bearing retainer sub-assembly into the transfer case, remove the SST(s).





f. Tighten the 7 bolts.
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)
55. INSPECT BACKLASH





a. Set the dial gauge perpendicular to the ring gear face, fix the driven pinion, and check backlash by moving the ring gear.
Backlash: 0.10 to 0.15 mm (0.0039 to 0.0059 inch)

NOTICE: Measure it at 3 points or more on the ring gear periphery.





b. If the measured value is out of standard, select a proper washer for the center differential case tapered roller bearing on the LH side from the table and install it to obtain the standard value.

HINT: When the backlash is larger or smaller than the standard, select a thinner or thicker washer respectively.





c. Ring gear mounting case plate washer location is shown in the illustration.





56. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVEN PINION
a. Apply red lead primer thinly and uniformly to both faces of the ring gear and rotate it several times.

NOTICE: Check the tooth contact on the ring gear at 4 places or more.





b. Observe the pattern shown by red lead primer.





c. In case of poor tooth contact, select a washer for the driven pinion bearing front side from the following table and replace it.

NOTICE: If the washer thickness is changed, the backlash will be also changed.





d. The location of the transfer output washer for tooth contact adjustment is shown in the illustration.
57. ADJUST TOTAL PRELOAD





a. Using SST(s) and a torque wrench, measure the initial torque with the driven pinion being contact with the ring gear face.
SST 09326-20011
Torque:
New bearing:
Driven pinion preload +0.2 to 0.4 Nm (+2.3 to 3.9 kgf-cm, 1.8 to 3.5 inch lbs.)
Used bearing:
Driven pinion preload +0.15 to 0.30 Nm (+1.6 to 3.1 kgf-cm, 1.3 to 2.7 inch lbs.)

NOTICE: Before measurement, rotate the bearing in both directions several times to make it fit.

HINT: Use a torque wrench with a fulcrum length of 160 mm (6.30 inch)





b. If the value is out of standard range, select the washer for the center differential case tapered roller bearing RH side from the following table and replace it.





c. The location of the transfer ring gear mounting case washer No.2 for preload adjustment is shown in the illustration.





d. Using a chisel, stake the transfer gear nut.
58. REMOVE TRANSFER RH BEARING RETAINER SUB-ASSEMBLY





a. Remove the 7 bolts from the transfer RH bearing retainer sub-assembly.





b. Using a screwdriver and a hammer, make a opening between the transfer RH bearing retainer sub-assembly and the transfer case.

NOTICE: Be careful not to damage the transfer RH bearing retainer sub-assembly and the transfer case.





c. Using SST(s), remove the transfer RH bearing retainer sub-assembly from the transfer case.
SST 09520-10021





59. REMOVE CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING
a. Fix the transfer RH bearing retainer sub-assembly in a vise.
b. Using SST(s), remove the center differential case tapered roller bearing RH outer race and transfer ring gear mounting case washer No.2 from the transfer RH bearing retainer sub-assembly.
SST 09308-00010





60. INSTALL SIDE GEAR SHAFT HOLDER BEARING
a. Install the side gear shaft holder bearing to the transfer RH bearing retainer sub-assembly.
b. Using snap ring pliers, install the side gear shaft holder hole snap ring.

HINT: Check that the side gear shaft holder hole snap ring fits in the groove of the transfer RH bearing retainer sub-assembly.





61. INSTALL TRANSFER RH BEARING RETAINER OIL SEAL
a. Using SST(s) and a press, install the transfer RH bearing retainer oil seal No.2 to the transfer RH bearing retainer sub-assembly.
SST 09950-60010 (09951-00350, 09951-00560, 09952-06010), 09950-70010 (09951-07150)

NOTICE: Carefully press-fit so that the oil seal will not be tilted.

b. Apply small amount of MP grease No.2 to the oil seal lip.
62. INSTALL TRANSFER RING GEAR MOUNTING CASE WASHER NO.2
a. Install the selected transfer ring gear mounting washer No.2 to the transfer RH bearing retainer sub-assembly.





63. INSTALL CENTER DIFFERENTIAL CASE TAPERED ROLLER BEARING
a. Using SST(s) and a press, install the center differential case tapered roller bearing RH outer race to the transfer RH bearing retainer sub-assembly.
SST 09950-60010 (09951-00620), 09950-70010 (09951-07150)





64. INSTALL O-RING
a. Coot the 2 O-rings with hypoid gear oil.
b. Install the 2 O-rings to the transfer RH bearing retainer sub-assembly.

NOTICE: Be careful not to twist the O-ring and fit it properly in the retainer's groove.

65. INSTALL TRANSFER RH BEARING RETAINER SUB-ASSEMBLY





a. Place the transfer with the surface where the transfer RH bearing retainer sub-assembly is facing up.
b. Align the centers of the transfer ring gear mounting case and the transfer case.





c. Insert SST(s) into the transfer RH bearing retainer sub-assembly.
SST 09387-00090

NOTICE: Insert SST(s) straight in order not to damage the oil seal.





d. Insert the transfer RH bearing retainer sub-assembly together with SST(s) into the transfer case.

NOTICE:
^ Avoid interference between the case and the retainer, and between the SST(s) and the transfer ring gear mounting case.
^ Carefully check the retainer's O-ring for damage and incorrect fitting.

HINT: If the retainer cannot be inserted into the case, tap it in with a plastic hammer.





e. After inserting the transfer RH bearing retainer sub-assembly into the transfer case, remove the SST(s).





f. Tighten the 7 bolts.
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)





66. INSPECT TOTAL PRELOAD
a. Using SST(s) and a torque wrench, measure the initial torque with the driven pinion being in contact with the ring gear face.
SST 09326-20011
Torque:
New bearing:
Driven pinion preload +0.2 to 0.4 Nm (+2.3 to 3.9 kgf-cm, 1.8 to 3.5 inch lbs.)
Used bearing:
Driven pinion preload +0.15 to 0.30 Nm (+1.6 to 3.1 kgf-cm, +1.3 to 2.7 inch lbs.)

HINT: Use a torque wrench with a fulcrum length of 160 mm (6.30 inch)





67. INSTALL TRANSFER RH BEARING RETAINER OIL SEAL
a. Using SST(s), install the transfer RH bearing retainer oil seal to the transfer RH bearing retainer sub-assembly to the position as shown in the illustration.
SST 09223-46011

NOTICE: Install the oil seal carefully so that it will not be tilted.

b. Apply MP grease to the oil seal lip.





68. INSTALL TRANSFER CASE OIL SEAL
a. Using SST(s), install the transfer case oil seal to the transfer case at the position as shown as in the illustration.
SST 09387-00010, 09950-70010 (09951-07150)

NOTICE: Install the oil seal carefully so that it will not be tilted.

b. Apply small amount of MP grease to the oil seal lip.
69. INSTALL CTR DIFFERENTIAL LOCK SLEEVE





a. Coat a new O-ring with hypoid gear oil.
b. Install the O-ring to the CTR differential lock sleeve.

NOTICE: Be careful not to twist the O-ring and fit it properly in the retainer's groove.





c. Using SST(s), install the CTR differential lock sleeve to the transfer case.
SST 09950-60010 (09951-00610), 09950-70010 (09951-07150)





d. Using snap ring pliers, install the shaft snap ring.

NOTICE: Check that the snap ring is fitted in the groove of the ring gear mounting case.





70. INSTALL TRANSFER EXTENSION HOUSING TYPE T OIL SEAL
a. Using SST(s), install the transfer extension housing type T oil seal to the transfer extension housing at the position as shown in the illustration.
SST 09950-60010 (09951-00380, 09951-00580, 09952-06010), 09950-70010 (09951-07150)

NOTICE: Install the oil seal carefully so that it will not be tilted.

b. Apply small amount of MP grease No. 2 to the oil seal lip.





71. INSTALL TRANSFER EXTENSION HOUSING DUST DEFLECTOR
a. Using SST(s) and a press, install a new transfer extension housing dust deflector to the transfer extension housing sub-assembly.
SST 09950-60020 (09951-00710), 09950-70010 (09951-07150)
72. INSTALL TRANSFER EXTENSION HOUSING SUB-ASSEMBLY





a. Apply sealant 1281 to the transfer extension housing sub-assembly in continuous beaded form of 1.2 mm diameter as shown in the illustration.

NOTICE:
^ Wipe any grease off from the attaching surfaces.
^ Install the transfer extension housing sub-assembly with in 10 minutes after applying the sealant.





b. Install the transfer extension housing sub-assembly to the transfer case with the 4 bolts.
Torque: 26 Nm (260 kgf-cm, 19 ft. lbs.)
c. Remove the transfer assembly from the overhaul attachment.





73. INSTALL TRANSFER & TRANSAXLE SETTING STUD BOLT
a. Install the transfer & transaxle setting stud bolts to the parts of the transfer case as shown in the illustration.
Torque: 39 Nm (400 kgf-cm, 30 ft. lbs.)

NOTICE: Install the sealant-coated side of the transfer & transaxle stud bolt to the transfer case.





74. INSTALL TRANSFER CASE STRAIGHT PIN
a. Using a plastic hammer, install the transfer case straight pins to the transfer case as shown in the illustration.





75. INSTALL TRANSFER DYNAMIC DAMPER
a. Install the transfer dynamic damper to the transfer extension housing sub-assembly with the 3 bolts.
Torque: 26 Nm (260 kgf-cm, 19 ft. lbs.)





76. INSTALL BREATHER OIL DEFLECTOR
a. Install the breather oil deflector to the transfer case cover No.1 with the bolt.
Torque: 6.5 Nm (66 kgf-cm, 57 inch lbs.)

NOTICE: Be careful about the direction of the deflector's fold.

77. INSTALL TRANSFER CASE COVER NO.1





a. Apply sealant 1281 to the transfer case cover No.1 in a continuous bead of 1.2 mm diameter as shown in the illustration.

NOTICE:
^ Wipe any grease off from the attaching surfaces.
^ Install the transfer case cover No.1 within 10 minutes after application of the sealant.





b. Install the transfer case cover No.1 to the transfer case with the 8 bolts.
Torque: 20 Nm (200 kgf-cm, 14 ft. lbs.)





78. INSTALL TRANSFER CASE BREATHER PLUG
a. Using SST(s) and a hammer, install the transfer case breather plug to the transfer case cover No.1.
SST 09612-10061





79. INSTALL TRANSFER COVER GASKET
a. Install a new transfer cover gasket to the transfer case.





80. INSTALL TRANSFER ASSEMBLY
a. Apply sealant 1281 to the transaxle assembly and the transfer assembly in continuous beaded form of 1.2 mm diameter as shown in the illustration.

NOTICE:
^ Wipe any grease off from the attaching surfaces.
^ Install it within 10 minutes after applying the sealant.
^ Sealant stuck on the gasket, case oil seal and driving plug may cause oil leakage and seizure due to oil shortage. Care must be taken.





b. Install the transfer assembly to the transaxle assembly with the 2 bolts and 6 nuts.
Torque: 69 Nm (700 kgf-cm, 51 ft. lbs.)

NOTICE:
^ Check that the gasket is installed to the transfer assembly before instating them to the transaxle assembly.
^ Install the transfer assembly to the transaxle assembly without tilting.
^ When moving the transfer assembly, do not hold the oil seal on both sides.

81. INSTALL AUTOMATIC TRANSMISSION W/TRANSFER
82. INSTALL TRANSFER STIFFENER PLATE RH
83. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE





84. INSTALL TRANSFER DRAIN PLUG
a. Install the transfer drain plug with a new drain gasket.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
85. INSTALL TRANSFER CASE NO.2 PLUG
a. Install the transfer case No.2 plug with a new gasket No.2.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
86. INSTALL TRANSFER CASE NO.1 PLUG
a. Add oil up to 0 to 5 mm below the lower side of the plug hole.
Oil quantity: 0.9 L (0.95 US hits, 0.71 Imp. qts)

HINT: When adding oil, pour it slowly.

b. Install the transfer case No.1 plug with a new gasket No. 1.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)