Overhaul (Assembly)
Assembly1. Assemble front case.
a. Install main gear assembly by tapping lightly using a soft hammer, as shown.
b. Apply sealant to the mating surface and bolts of front case cover, then attach it to the front case.
^ Use Genuine Anaerobic Liquid Gasket or equivalent.
^ These ten bolts should be coated with sealant.
Bolts A: 20 - 24 Nm (2.0 - 2.4 kg-m, 14 - 17 ft. lbs.)
Bolts B: 24 - 28 Nm (2.4 - 2.9 kg-m, 17 - 21 ft. lbs.)
c. Apply ATF to needle bearing and install it into main gear.
d. Install counter gear assembly by tapping lightly using a soft hammer, as shown.
e. Install cross shaft and inner shift lever.
^ When replacing cross shaft, outer shift lever or outer shift lever lock pin, replace them as a set.
f. Apply sealant to plug and install it into front case using a soft hammer, as shown.
Use Genuine Anaerobic Liquid Gasket or equivalent.
g. Insert interlock plunger into front case.
h. Install L & H shift rod and fork assembly with coupling sleeve.
i. Install 2-4 shift rod.
j. Install transfer neutral position switch, check balls, check springs and plugs.
^ Apply sealant to switches and plugs.
^ Use Genuine Anaerobic Liquid Gasket or equivalent.
2. Select counter gear rear bearing shim.
a. Seat counter gear assembly using Tool, as shown.
b. Place J34291-1 (bridge), J34291-2 (legs) and J34291-5 (gauging cylinder) on machined surface of center case, allowing J34291-5 (gauging cylinder) to rest on top outer portion of counter gear rear bearing. Lock J34291-5 (gauging cylinder) in place.
c. Insert J34291-20 (gauging plunger) into J34291-5 (gauging cylinder).
d. Place J34291-1 (bridge), J34291-2 (legs), J34291-5 (gauging cylinder) and J34291-20 (gauging plunger) onto machined surface of front case assembly, allowing gauging plunger to drop until it contacts counter gear rear bearing mating surface.
e. Lock J34291-20 (gauging plunger) in place and use feeler gauge to measure end play between J34291-5 (gauging cylinder) and J34291-20 (gauging plunger).
f. Use measured distance to select correct counter gear rear bearing shim.
Allowable counter gear end play: 0 - 0.2 mm (0 - 0.0079 inch)
Allowable counter gear rear bearing shim: Refer to Specifications.
3. Place suitable shim with grease on counter gear rear bearing.
4. Apply ATF to each part in front case.
5. Assemble center case assembly as follows:
a. Install mainshaft on center case by tapping lightly using a soft hammer, as shown.
^ Apply ATF to mainshaft front bearing.
b. Install bearing retainer.
Bearing retainer: 16 - 21 Nm (1.6 - 2.1 kg-m, 12 -15 ft. lbs.)
c. Put drive chain onto the front drive sprocket and front drive shaft, and then put them in center case.
d. Install front drive shaft by tapping lightly using a soft hammer, as shown.
^ Make sure shafts are aligned in the case.
e. Apply ATF to needle bearings and install them into front drive sprocket.
^ These needle bearings can be installed more easily if front drive sprocket is rotated while installing them.
f. Install 2-4 coupling sleeve with 2-4 shift fork.
^ Pay special attention to direction of coupling sleeve.
g. Install shifting inserts and spread spring.
^ Pay attention to the direction of shifting inserts.
h. Install baulk ring, then install clutch gear and mainshaft rear bearing using a drift, as shown.
^ Place wooden block under mainshaft in order to protect mainshaft front bearing.
i. Install spacer.
j. Select and install snap ring with proper thickness.
Allowable clearance between snap ring and groove: 0 - 0.15 mm (0 - 0.0059 inch)
Available snap ring for mainshaft rear bearing: Refer to Specifications.
k. Install steel ball, speedometer drive gear and retainer ring.
^ Steel ball is the smallest of check balls for this unit.
l. Install low gear and its bearing onto mainshaft.
^ Apply ATF to needle bearing.
m. Install L & H hub and snap ring to mainshaft using a drift, as shown.
^ Pay attention to direction of L & H hub.
n. Measure low gear end play.
Low gear end play: 0.2 - 0.35 mm (0.0079 - 0.0138 inch)
6. Apply sealant to mating surface of center case then attach to front case and tighten bolts.
^ Use Genuine Anaerobic Liquid Gasket or equivalent.
7. Install snap ring to 2-4 shift rod using snap ring pliers, as shown.
8. Install oil gutter and oil cover.
9. Apply ATF to each part in center case.
10. Apply sealant to mating surface of rear case then attach it to center case and tighten bolts.
^ Use Genuine Anaerobic Liquid Gasket or equivalent.
11. Install 4WD switch.
^ Apply sealant to switch threads.
^ Use Genuine Anaerobic Liquid Gasket or equivalent.
12. Install the companion flange and the companion flange nut using Tool, as shown.
^ Tighten the companion flange to specification. Refer to "Gear Components".