Part 3

TRANSFER ASSEMBLY (4WD)
OVERHAUL





65. INSPECT TOTAL PRELOAD
a. Using SST and a torque wrench, measure the initial torque with the driven pinion being contact with the ring gear face.
SST 09326-20011
Torque:
New bearing:
Driven pinion preload +0.2 - 0.4 Nm (+2.3 - 3.9 kgf-cm, +1.8 - 3.5 inch lbs.)
Used bearing:
Driven pinion preload +0.15 - 0.30 Nm (+1.6 - 3.1 kgf-cm, +1.3 - 2.7 inch lbs.)

HINT: Use a torque wrench with a fulcrum length of 160 mm (6.30 inch)





66. INSTALL TRANSFER RH BEARING RETAINER OIL SEAL
a. Using SST, drive the oil seal into the right bearing retainer to the position shown in the illustration.
SST 09223-46011

NOTICE: Drive it in carefully so that it will not be tilted.

b. Apply MP grease to the oil seal lip.





67. INSTALL TRANSFER CASE OIL SEAL
a. Using SST, drive the case oil seal into the case to the position shown in the illustration.
SST 09387-00010, 09950-70010 (09951-07150)

NOTICE: Drive it in carefully so that it will not be tilted.

b. Apply small amount of MP grease to the oil seal lip.
68. INSTALL CTR DIFFERENTIAL LOCK SLEEVE





a. Apply hypoid gear oil to a new O-ring.
b. Install the O-ring to the center differential lock sleeve.

NOTICE: Be careful not to twist the O-ring and fit it into the retainer's groove properly.





c. Using SST, install the center differential lock sleeve to the case.
SST 09950-60010 (09951-00610), 09950-70010 (09951-07150)





d. Using a snap ring pliers, install the shaft snap ring.

NOTICE: Check that the snap ring is fitted in the groove of the center differential control coupling assembly.





69. INSTALL TRANSFER EXTENSION HOUSING TYPE T OIL SEAL
a. Using SST, drive the oil seal into the extension housing to the position shown in the illustration.
SST 09950-60010 (09951-00380, 09951-00580, 09952-06010), 09950-70010 (09951-07150)

NOTICE: Drive it in carefully so that it will not be tilted.

b. Apply small amount of MP grease No.2 to the oil seal lip.





70. INSTALL TRANSFER EXTENSION HOUSING DUST DEFLECTOR
a. Using SST and a press, install the dust deflector to the extension housing.
SST 09950-60020 (09951-00710), 09950-70010 (09951-07150)
71. INSTALL TRANSFER EXTENSION HOUSING SUB-ASSEMBLY





a. Apply sealant 1281 to the extension housing in continuous beaded form of 1.2 mm diameter as shown in the illustration.

NOTICE:
^ Remove any grease from the attaching surfaces.
^ Attach it within 10 minutes. after application of the sealant.





b. Install the extension housing to the case with the 4 bolts.
Torque: 26 Nm (260 kgf-cm, 19 ft. lbs.)
c. Remove the transfer assembly from the overhaul attachment.





72. INSTALL TRANSFER & TRANSAXLE SETTING STUD BOLT
a. Install the stud bolts to the parts of the case as shown in the illustration.
Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)

NOTICE: Install the stud bolt as its sealant-coated side faces the case.





73. INSTALL TRANSFER CASE STRAIGHT PIN
a. Using a plastic hammer, drive the straight pins into the transfer assembly case as shown in the illustration.





74. INSTALL TRANSFER DYNAMIC DAMPER
a. Install the dynamic damper to the extension housing with the 3 bolts.
Torque: 26 Nm (260 kgf-cm, 19 ft. lbs.)





75. INSTALL BREATHER OIL DEFLECTOR
a. Install the breather oil deflector to the case cover with the bolt.
Torque: 6.5 Nm (66 kgf-cm, 57 inch lbs.)

NOTICE: Be careful about the direction of the deflector's folding.

76. INSTALL TRANSFER CASE COVER NO.1





a. Apply sealant 1281 to the case cover in continuous beaded form of 1.2 mm diameter as shown in the illustration.

NOTICE:
^ Remove any grease from the attaching surfaces.
^ Attach it within 10 minutes after application of the sealant.





b. Install the case cover to the case with the 8 bolts.
Torque: 20 Nm (200 kgf-cm, 14 ft. lbs.)





77. INSTALL TRANSFER CASE BREATHER PLUG
a. Using SST and a hammer, install the breather plug to the case cover.
SST 09612-10061





78. INSTALL TRANSFER COVER GASKET
a. Install a new gasket to the case.
79. INSTALL TRANSFER ASSEMBLY





a. Apply sealant 1281 to the transaxle assembly and the transfer assembly in continuous beaded form of 1.2 mm diameter as shown in the illustration.

NOTICE:
^ Remove any grease from the attaching surfaces.
^ Install it within 10 minutes after application of 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 instating 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 by both sides.

80. AUTOMATIC TRANSMISSION W/TRANSFER
81. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE





82. INSTALL TRANSFER DRAIN PLUG
a. Install the drain plug with a new gasket.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
83. INSTALL TRANSFER CASE NO.2 PLUG
a. Install the No.2 plug with a new gasket.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
84. INSTALL TRANSFER CASE NO.1 PLUG
a. Supply oil up to the level 0 - 5 mm below the lowest end of the plug hole.
Oil quantity: 0.9 L (0.95 US qts., 0.71 Imp. qts.)

NOTICE: When supplying oil, fill it slowly.

b. Install the No.1 plug with a new gasket.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
85. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
86. CHECK ABS SPEED SENSOR SIGNAL
a. ABS WITH EBD & BA & TRAC & VSC SYSTEM