Transfer Unit Replacement

TRANSFER ASSEMBLY

Components:

REMOVAL
1. REMOVE ENGINE AND TRANSAXLE
2. REMOVE TRANSFER STIFFENER PLATE RH
3. REMOVE AUTOMATIC TRANSMISSION W/TRANSFER





4. REMOVE TRANSFER CASE NO. 1 PLUG
a. Remove the transfer case No. 1 plug.
b. Remove the gasket No. 1 from the transfer case No.1 plug.
5. REMOVE TRANSFER CASE NO. 2 PLUG
a. Remove the transfer case No. 2 plug.
b. Remove the gasket No. 2 from the transfer case No. 2 plug.
6. REMOVE TRANSFER DRAIN PLUG
a. Remove the transfer drain plug and bleed the oil.
b. Remove the drain gasket from the transfer drain plug.





7. REMOVE TRANSFER ASSEMBLY
a. Remove the 2 bolts and 6 bolts.
b. Using a plastic hammer, remove the transfer assembly from the transaxle assembly.

NOTICE:
^ Remove the transfer assembly from the transaxle assembly without tilting it.
^ When removing the transfer assembly, do not hold onto the oil seal parts on both sides of the assembly.

INSTALLATION





1. INSTALL TRANSFER ASSEMBLY
a. Apply sealant 1281 to the transaxle assembly and transfer assembly in continuous beaded from 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 installing 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 the both sides.

2. INSTALL AUTOMATIC TRANSMISSION W/ TRANSFER
3. INSTALL TRANSFER STIFFENER PLATE RH
4. INSTALL ENGINE AND TRANSAXLE





5. INSTALL TRANSFER DRAIN PLUG
a. Install the transfer drain plug with a new drain gasket.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
6. 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.)
7. 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 qts, 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.)