Shift on the fly system installation

Part name

Tightening torque

9: 75 N・m { 7.6 kgf・m / 55 lb・ft }

11: 50 N・m { 5.1 kgf・m / 37 lb・ft }

12: 50 N・m { 5.1 kgf・m / 37 lb・ft }

13: 50 N・m { 5.1 kgf・m / 37 lb・ft }

16: 9 N・m { 0.9 kgf・m / 80 lb・in }

17: 88 N・m { 9.0 kgf・m / 65 lb・ft }

When assembling, if nothing in particular is specified, refer to the following and apply or add shift-on-the-fly system oil.

Refer to "201.General Information 14B.Vehicle Information recommended fluids, lubricants and diesel fuels".

1) Clean the housing contact surface of the front axle case.

2) Install the inner drive shaft to the front axle case.

3) Install the snap ring to the front axle case groove.

4) Apply shift-on-the-fly system oil to the sleeve.

5) Install the sleeve to the axle shaft.

1) Apply shift-on-the-fly system oil to the clutch gear.

2) Install the clutch gear to the inner drive shaft.

3) Apply differential oil to the sleeve.

4) Install the sleeve to the inner drive shaft.

5) Remove any old sealing agent from the following parts.

6) Apply LOCTITE FMD-127 or equivalent to the following parts.

Legend

Dimensions

a. Diameter 106 mm {4.17 in}

b. Diameter 83 mm {3.27 in}

7) Install the housing to the front axle case.

Tightening torque: 75 N・m { 7.6 kgf・m / 55 lb・ft }

1) Clean the contact surface of the housing and shift-on-the-fly actuator.

2) Apply LOCTITE FMD-127 or equivalent to the contact surface between the shift-on-the-fly actuator and the housing.

3) Remove any old sealing agent from the bolt and threaded hole.

4) Apply LOCTITE FMD-127 or equivalent to the bolt.

5) Install the shift-on-the-fly actuator to the housing.

Tightening torque: 9 N・m { 0.9 kgf・m / 80 lb・in }

1) Remove any old sealing agent from the following parts.

2) Apply LOCTITE FMD-127 or equivalent to the following parts.

Legend

Dimensions

a. Diameter 63.5 mm {2.50 in}

b. Diameter 82 mm {3.23 in}

3) Install the inside drive shaft to the front axle case and housing.

Tightening torque: 88 N・m { 9.0 kgf・m / 65 lb・ft }

1. Preparations for wheel speed sensor installation

1) Clean the following sections.

2. Precautions for wheel speed sensor installation

3. Installation (ABS-specification 2WD (High ride suspension specifications), ABS-specification 4WD)

1) Install the wheel speed sensor to the knuckle.

Tightening torque: 8.2 N・m { 0.8 kgf・m / 73 lb・in }

2) Install the harness bracket to the upper link and knuckle.

Tightening torque: 8.2 N・m { 0.8 kgf・m / 73 lb・in } Harness bracket tightening bolt

Tightening torque: 8.2 N・m { 0.8 kgf・m / 73 lb・in } Harness bracket tightening nut

3) Connect the harness clips to the harness as indicated by the arrows in the following diagram.

Legend

4) Connect the harness connector to the wheel speed sensor.

5) Make sure that the harness is not twisted.

4. Inspection after vehicle restoration

1) Turn ON the ignition switch, and check whether the ABS warning light turns OFF after illuminating for approximately 3 seconds.

2) Start the engine and drive the vehicle straight forward from a stationary state. Slowly accelerate to 15 km/h {9.3 mph} and then slowly apply the brake until the vehicle stops. Check that there are no abnormal noises or problems with the braking force during this procedure.

3) Confirm whether the following symptom occurs during verification actions above.

4) When the above symptom occurs, take the following action.

1) Fill the outside drive shaft double offset joint section with grease.

Standard: 135 g { 4.8 oz }

2) Install the outside drive shaft to the inside drive shaft.

3) Move the outside drive shaft double offset joint section in the vertical direction several times.

4) Install the circlip to the double offset joint case.

Legend

Legend

5) Install large boot band A to boot A.

6) Stake large boot band A using the special tool.

SST: 5-8840-2745-0 - clamp plier

Standard: 0.4 mm or less { 0.016 in or less } Difference between a and b

Dimensions

a: 1.2 to 4.0 mm { 0.05 to 0.16 in }

b: 1.2 to 4.0 mm { 0.05 to 0.16 in }

1) Install the knuckle to the upper control arm.

Tightening torque: 98 N・m { 10.0 kgf・m / 72 lb・ft }

2) Install the cotter pin upper control arm.

3) Connect the lower ball joint to the knuckle.

Tightening torque: 147 N・m { 15.0 kgf・m / 108 lb・ft }

4) Install the cotter pin to the lower ball joint.

5) Referring to the following, adjust the trim height.

Refer to "3.Driveline, Axle 3C.Drive Shaft System wheel alignment check".

1) Connect the tie rod end to the knuckle.

2) Install the castle nut to the ball joint.

Tightening torque: 98 N・m { 10.0 kgf・m / 72 lb・ft }

3) Install the cotter pin to the ball joint.

1) Install the dust cover to the knuckle.

1) Install the front hub and brake rotor to the knuckle.

2) Install the bolt to the knuckle.

Tightening torque: 85 N・m { 8.7 kgf・m / 63 lb・ft }

3) Install the washer and lock nut to the front hub.

Tightening torque: 127 N・m { 13.0 kgf・m / 94 lb・ft }

Legend

4) Install the cotter pin to the front hub.

5) Install the hub cap to the front hub.

1) Install the brake support to the knuckle.

Tightening torque: 205 to 245 N・m { 20.9 to 25.0 kgf・m / 151 to 181 lb・ft }

2) Install the disc brake pad and shim to the brake support.

3) Install the brake caliper to the brake support.

4) Install the lock bolt to the brake caliper.

Tightening torque: 32 to 42 N・m { 3.3 to 4.3 kgf・m / 24 to 31 lb・ft }

1. Regarding lubricant refill amount and type

For the lubricant refill amount, refer to the following.

Refer to "204.Driveline, Axle 17B.Maintenance Information primary specifications of driveline, axle".

For the lubricant type, refer to the following.

Refer to "201.General Information 14B.Vehicle Information recommended fluids, lubricants and diesel fuels".

2. Front final drive lubricant refill procedure

1) Install the drain plug and gasket to the front drive axle.

Tightening torque: 50 N・m { 5.1 kgf・m / 37 lb・ft }

2) Add differential oil to the front drive axle.

Legend

3) Install the filler plug and gasket to the front drive axle.

Tightening torque: 50 N・m { 5.1 kgf・m / 37 lb・ft }

1. Regarding lubricant type

For the lubricant type, refer to the following.

Refer to "201.General Information 14B.Vehicle Information recommended fluids, lubricants and diesel fuels".

2. Lubricant refill procedure

1) Remove the filler plug and gasket from the housing.

2) Add shift-on-the-fly system oil to the housing.

Legend

3) Install the filler plug and gasket to the housing.

Tightening torque: 50 N・m { 5.1 kgf・m / 37 lb・ft }

1. Models with front and rear underguards (long type)

1) Install the front underguard to the frame.

Tightening torque: 42 N・m { 4.3 kgf・m / 31 lb・ft }

2) Install the rear underguard (long type) to the frame.

Tightening torque: 42 N・m { 4.3 kgf・m / 31 lb・ft }

Legend

2. Models with front and rear underguards (short type)

1) Install the front underguard to the frame.

Tightening torque: 42 N・m { 4.3 kgf・m / 31 lb・ft }

2) Install the rear underguard (short type) to the frame.

Tightening torque: 42 N・m { 4.3 kgf・m / 31 lb・ft }

Legend

3. Models with front and rear underguards and oil pan guard.

1) Install the front underguard to the frame.

Tightening torque: 42 N・m { 4.3 kgf・m / 31 lb・ft }

2) Install the rear underguard to the frame.

Tightening torque: 42 N・m { 4.3 kgf・m / 31 lb・ft }

3) Install the oil pan guard to the frame.

Tightening torque: 42 N・m { 4.3 kgf・m / 31 lb・ft }

Legend

Legend

1. Models with aluminum wheels

1) Temporarily tighten the disc wheel to the vehicle.

2) Lower vehicle.

3) Final tighten the wheel nut in the order shown in the diagram.

Tightening torque: 120 N⋅m {12 kgf⋅m / 87 lb⋅ft}

Standard: 50 to 100 km { 31 to 62 mile }

4) Install the wheel cap to the disc wheel.

5) Check that the surfaces of the wheel cap and wheel are flat.

Legend

2. Models with steel wheels

1) Temporarily tighten the disc wheel and wheel cap to the vehicle.

2) Lower vehicle.

3) Final tighten the wheel nut in the order shown in the diagram.

Tightening torque: 120 N⋅m {12 kgf⋅m / 87 lb⋅ft}

Standard: 50 to 100 km { 31 to 62 mile }

Refer to "3.Driveline, Axle 3C.Drive Shaft System wheel alignment check".

1. Post procedures

1) Connect the battery cable to the battery negative terminal.

2) Referring to the following, perform the setting of the front door power window switch with AUTO UP/AUTO DOWN function.

Refer to "9.Body, Cab, Accessories 9T.Glass, Windows, Mirrors front door power window switch setting".

3) Close the engine hood.