TRANSFER ASSEMBLY

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Before Service Precautions

•  Assemble with bare hands or using vinyl gloves. To prevent foreign material from entering the transfer, do not use cotton work gloves or a rag.
•  Apply sufficient gear oil to the sliding surfaces and O-rings, and be careful not to damage when assembling.
•  Replace the transfer with a new one if the case alignment surface is damaged. Be careful not to damage it since it may cause oil leakage.
•  When installing silicone sealant, clean off the old sealant adhering to the sealing area and clean the sealing area with cleaning fluids.
•  After installing a seal, leave the parts alone for 2 h or more. Do not add oil or operate the vehicle during this time.

Transfer Assembly

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1
Front case
2
Oil seal (control rod)
(See Oil Seal (control rod) Assembly Note.)
3
Oil seal (front case)
(See Oil Seal (front case) Assembly Note.)
4
Maindrive gear
5
Retainer
6
Maindrive gear bearing
(See Maindrive Gear Bearing Assembly Note.)
7
Retaining ring
(See Maindrive Gear Bearing Assembly Note.)
8
Retaining bolt
9
Baffle plate
10
Countershaft rear bearing (center case side)
(See Countershaft Bearing Assembly Note.)
11
Countershaft front bearing (front case side)
(See Countershaft Bearing Assembly Note.)
12
Countershaft
(See Countershaft Assembly Note.)
13
Adjustment shim
(See Countershaft Assembly Note.)
14
H/L hub sleeve
15
H/L shift fork
16
Plunger
17
Spring
18
Plain washer
19
Snap ring
20
H/L shift rod
21
Snap ring
22
Interlock pin
23
2W/4W shift end
24
2W/4W shift rod
25
Steel ball
26
Spring
27
Retaining bolt
28
Needle bearing
29
Mainshaft
(See Mainshaft and Mainshaft Center Bearing Assembly Note.)
30
Mainshaft center bearing
(See Mainshaft and Mainshaft Center Bearing Assembly Note.)
31
Retaining ring
32
Retaining ring
(See Mainshaft and Mainshaft Center Bearing Assembly Note.)
33
Needle bearing
34
Low gear
35
H/L clutch hub
36
Retaining ring
37
Center case
(See Center Case Assembly Note.)
38
Oil passage
(See Oil Passage Assembly Note.)
39
Oil catcher
(See Oil Catcher Assembly Note.)
40
Center bearing retainer
41
Sprocket
(See Chain, Front Drive Shaft and Sprocket Assembly Note.)
42
Front drive shaft bearing (rear case side)
(See Front Drive Shaft Bearing Assembly Note.)
43
Front drive shaft bearing (center case side)
(See Front Drive Shaft Bearing Assembly Note.)
44
Front drive shaft
(See Chain, Front Drive Shaft and Sprocket Assembly Note.)
45
Chain
(See Chain, Front Drive Shaft and Sprocket Assembly Note.)
46
Needle bearing
(See Chain, Front Drive Shaft and Sprocket Assembly Note.)
47
Snap ring
48
Collar
49
Spring
50
2W/4W hub sleeve
51
2W/4W shift fork
52
Spacer
53
Snap ring
54
2W/4W clutch hub
(See 2W/4W Clutch Hub Assembly Note.)
55
Mainshaft rear bearing
(See Mainshaft Rear Bearing Assembly Note.)
56
Speed drive gear
57
Rear case
(See Rear Case Assembly Note.)
58
Oil seal (center case)
(See Oil Seal (center case) Assembly Note.)
59
Companion flange (center case side)
60
Oil seal (rear case)
(See Oil Seal (rear case) Assembly Note.)
61
Companion flange (rear case side)
62
Control rod
63
Control rod end
64
Guide plate
65
Reverse gate lever
66
Reverse gate spring
67
Spacer
68
E-ring
69
Control case
(See Control Case Assembly Note.)


Oil Seal (control rod) Assembly Note

Caution
•  Assemble the oil seal being careful not to assemble it in the incorrect direction.

1.  Apply specified grease to the lip of a new oil seal.

2.  Install the oil seal (control rod) using the SST.

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Installation depth A: 0 mm {0 in}


Oil Seal (front case) Assembly Note

1.  Apply specified grease to the lip of a new oil seal.

2.  Install the oil seal (front case) using the SST.

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Installation depth A: 2.4—3.0 mm {0.095—0.118 in}


Maindrive Gear Bearing Assembly Note

1.  Assemble the maindrive gear bearing using the SST and press.

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2.  Install the retaining ring.

3.  Measure the clearance between the retaining ring and groove of the maindrive gear.

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•  If not within the specification, adjust by choosing the proper retaining ring.
Maindrive gear bearing end play
0—0.15 mm {0.0—0.0059 in}

Maindrive gear bearing retaining ring

Thickness (mm {in})
2.60 {0.102}
2.67 {0.105}
2.74 {0.108}


Countershaft Bearing Assembly Note

1.  Assemble the countershaft bearing using the SSTs and press.

Front case side

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Center case side

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Countershaft Assembly Note

1.  Assemble the countershaft to the front case.

2.  Measure the depth A as shown in the figure.

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3.  Select the correct countershaft adjustment shim thickness.

Countershaft adjustment shim selective chart

Dimension A (mm {in})

Shim thickness (mm {in})
25.0—25.1
{0.985—0.988}
0.5 {0.020}
25.1—25.2
{0.989—0.992}
0.4 {0.016}
25.2—25.3
{0.993—0.996}
0.3 {0.012}
25.3—25.4
{0.997—1.000}
0.2 {0.008}
25.4—25.5
{1.000—1.003}
0.1 {0.004}
25.5—25.6
{1.004—1.007}
-

4.  Install the adjustment shim.


Mainshaft and Mainshaft Center Bearing Assembly Note

1.  Assemble the mainshaft center bearing using the SST and press.

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2.  Measure the clearance between the retaining ring and groove of the mainshaft.

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•  If not within the specification, adjust by choosing the proper retaining ring.
Mainshaft center bearing end play
0—0.15 mm {0.0—0.0059 in}

Mainshaft center bearing retaining ring

Thickness (mm {in})
3.1 {0.122}
3.2 {0.126}
3.3 {0.130}

3.  Assemble the mainshaft to the center case using the plastic hammer.


Center Case Assembly Note

1.  Apply sealant to the contact surfaces of the front case and center case as shown in the figure.

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2.  Assemble the center case.

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Bolt length (measured from below the head)
43 mm {1.69 in}


Oil Passage Assembly Note

1.  Assemble the oil passage to the center case.

Note
•  Align the oil passage of the center case groove as shown in the figure.
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Oil Catcher Assembly Note

1.  Align the oil catcher groove as shown in the figure.

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2.  Apply specified grease to the lip of a new oil seal.

3.  Install the oil catcher using the SST.

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Installation depth A: 0 mm {0 in}


Chain, Front Drive Shaft and Sprocket Assembly Note

1.  Assemble the chain, front drive shaft and sprocket as a single unit.

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Note
•  Assemble the front drive shaft using the plastic hammer.

2.  Install the needle bearings while turning the mainshaft.

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Front Drive Shaft Bearing Assembly Note

1.  Assemble the front drive shaft bearing using the SSTs and press.

Center case side

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Rear case side

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2W/4W Clutch Hub Assembly Note

1.  Assemble the 2W/4W clutch hub using the SST.

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Mainshaft Rear Bearing Assembly Note

1.  Assemble the mainshaft rear bearing using the SST.

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Rear Case Assembly Note

1.  Apply sealant to the contact surfaces of the center case and rear case as shown in the figure.

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2.  Assemble the rear case.

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Bolt length (measured from below the head)
A: 58 mm {2.28 in}
B: 113 mm {4.45 in}


Oil Seal (center case) Assembly Note

1.  Apply specified grease to the lip of a new oil seal.

2.  Install the oil seal (center case) using the SST.

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Installation depth A: 0 mm {0 in}


Oil Seal (rear case) Assembly Note

1.  Apply specified grease to the lip of a new oil seal.

2.  Install the oil seal (rear case) using the SST.

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Installation depth A: 6.7—7.3 mm {0.27—0.28 in}


Control Case Assembly Note

1.  Apply sealant to the contact surfaces of the control case and transfer case as shown in the figure.

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2.  Install the control case to the transfer case.