Shift on the fly system removal

1. Component views

Shift-on-the-fly system

Part name

  1. Sleeve
  2. Clutch gear
  3. Needle bearing
  4. Inner drive shaft
  5. Snap ring
  6. Inner shaft bearing
  7. Snap ring
  8. Oil seal
  9. Bolt
  10. Gasket
  11. Filler plug
  12. Drain plug
  13. Filler plug
  14. Housing
  15. Shift-on-the-fly actuator
  16. Bolt
  17. Bolt
  18. Front axle shaft

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 }

2. Preliminary and post procedures

1. Preliminary procedures

1) Open the engine hood.

2) Disconnect the battery cable from the battery negative terminal.

Caution

  • After turning OFF the ignition switch (power mode for models with passive entry and start system), do not disconnect the battery cable within 3 minutes.
  • If the battery cable is disconnected within 3 minutes, the vehicle electronic control system may malfunction.
  • If the battery cable is disconnected, perform the setting of the front door power window switch with AUTO UP/AUTO DOWN function after connecting the battery negative terminal.

3. Disc wheel removal

1. Models with aluminum wheels

1) Move the vehicle to a flat surface.

2) Pull the parking brake lever.

3) Secure the vehicle using chock blocks.

4) Raise the vehicle.

Note

  • Jack up the vehicle but not to an extent that the tire leaves the ground.

5) Remove the wheel cap from the disc wheel.

Note

  • Insert a tool with flat tip such as a flathead screwdriver into the wheel cap groove to remove.

Legend

  1. Wheel cap groove

6) Loosen the wheel nuts.

Note

  • Loosen without allowing the disc wheel to rattle.

Caution

  • At this time, do not remove the wheel nuts.

7) Raise the vehicle.

Note

  • Jack up the vehicle until the tire is completely off the ground.
  • Support the frame using a chassis stand as necessary.

8) Remove the disc wheel from the vehicle.

2. Models with steel wheels

1) Move the vehicle to a flat surface.

2) Pull the parking brake lever.

3) Secure the vehicle using chock blocks.

4) Raise the vehicle.

Note

  • Jack up the vehicle but not to an extent that the tire leaves the ground.

5) Remove the wheel cap from the disc wheel.

6) Loosen the wheel nuts.

Note

  • Loosen without allowing the disc wheel to rattle.

Caution

  • At this time, do not remove the wheel nuts.

7) Raise the vehicle.

Note

  • Jack up the vehicle until the tire is completely off the ground.
  • Support the frame using a chassis stand as necessary.

8) Remove the disc wheel and wheel cap from the vehicle.

4. Underguard removal

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

1) Remove the rear underguard (long type) from the frame.

2) Remove the front underguard from the frame.

Legend

  1. Front underguard
  2. Rear underguard (long type)
  3. Bolt
  4. Clip

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

1) Remove the rear underguard (short type) from the frame.

2) Remove the front underguard from the frame.

Legend

  1. Front underguard
  2. Rear underguard (short type)
  3. Bolt
  4. Clip

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

1) Remove the oil pan guard from the frame.

2) Remove the rear underguard from the frame.

3) Remove the front underguard from the frame.

Models with hydraulic power steering

Legend

  1. Front underguard
  2. Rear underguard
  3. Oil pan guard
  4. Bolt
  5. Clip

Models with electric power steering

Legend

  1. Front underguard
  2. Rear underguard
  3. Oil pan guard
  4. Bolt
  5. Clip

5. Differential oil drain

1) Dispose of the differential oil in the oil catcher tank.

2) Remove the filler plug and gasket from the front drive axle.

3) Remove the drain plug and gasket from the front drive axle, and drain the differential oil from the front drive axle.

6. Brake caliper removal

1) Remove the lock bolt from the brake caliper.

2) Remove the brake caliper from the brake support.

3) Remove the disc brake pad and shim from the brake support.

4) Remove the brake support from the knuckle.

7. Front hub removal

1) Remove the hub cap from the front hub.

2) Remove the following parts from the front hub.

  • Cotter pin
  • Lock nut
  • Washer

3) Remove the bolt from the knuckle.

4) Remove the front hub and brake rotor from the knuckle.

8. Dust cover removal

1) Remove the dust cover from the knuckle.

9. Power steering unit disconnect

1) Remove the cotter pin from the ball joint.

2) Remove the castle nut from the ball joint.

3) Disconnect the tie rod end from the knuckle using the special tool.


SST: 5-8840-2005-0 - ball joint remover

Legend

  1. 5-8840-2005-0

10. Knuckle removal

1) Disconnect the lower ball joint from the knuckle using the special tool.


SST: 5-8840-2017-0 - ball joint remover

Caution

  • Take care not to damage the ball joint boot.

Legend

  1. 5-8840-2017-0

2) Remove the knuckle from the upper ball joint using the special tool.


SST: 5-8840-2121-0 - upper ball joint remover

Caution

  • Take care not to damage the ball joint boot.

Legend

  1. 5-8840-2121-0

11. Outside drive shaft removal

1) Remove the 3 claws of large boot band A using a hammer and chisel.

2) Remove large boot band A from boot A.

Caution

  • Do not damage boot A when removing.
  • Do not reuse large boot band A.

Legend

  1. Boot band A

3) Remove the 3 claws of small boot band A using a hammer and chisel.

4) Remove small boot band A from boot A.

Caution

  • Do not damage boot A when removing.
  • Do not reuse small boot band A.

5) Remove the circlip from the inside drive shaft using a screwdriver or equivalent.

Legend

  1. Circlip

6) Remove the outside drive shaft from the inside drive shaft.

12. Wheel speed sensor removal

1. Precautions for wheel speed sensor removal

Caution

  • Be careful not to damage the wheel speed sensor during service works, since it may cause ABS failure.
  • Because ABS abnormalities or malfunctions may occur if the wheel speed sensor is improperly installed, follow the precautions detailed in the outlined procedure when installing, removing, or replacing the wheel speed sensor.
  • When it is difficult to remove the wheel speed sensor body due to rust, use rust penetrant etc., and then carefully remove the sensor body by shifting it little by little until it comes free.
  • Do not bump or step on the removed sensor.
  • Do not remove the sensor unit by hammering.
  • Do not insert a flat-head screwdriver or the like into the gap to remove it forcibly.
  • Do not pull the sensor harness.

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

1) Disconnect the harness connector from the wheel speed sensor.

2) Unlock the harness clips indicated by the arrows in the following diagram.

3) Remove the harness bracket from the upper link and knuckle.

4) Remove the wheel speed sensor from the knuckle.

Legend

  1. Connector position
  2. Wheel speed sensor
  3. Harness bracket tightening nut
  4. Harness bracket tightening bolt
  5. Wheel speed sensor tightening bolt

13. Inside drive shaft removal

1) Remove the axle mounting bracket bolt from the front axle case and housing.

2) Remove the inside drive shaft from the front axle case and housing.

14. Shift on the fly actuator removal

1) Remove the shift-on-the-fly actuator from the housing.

15. Clutch gear removal

1) Remove the housing from the front axle case.

2) Remove the sleeve from the inner drive shaft.

3) Remove the clutch gear from the inner drive shaft.

16. Inner drive shaft removal

1) Remove the snap ring from the front axle case using snap ring pliers.

2) Remove the snap ring from the inner drive shaft using snap ring pliers.

3) Remove the inner shaft bearing from the inner shaft using the special tool.


SST: 5-8840-2197-0 - separator

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