|
(1) |
Transmission case ASSY (Single-range) |
(7) |
Pitching stopper bracket |
(13) |
High-low cable bracket B (Dual-range) |
|
(2) |
Gasket |
(8) |
Oil level gauge (Non-turbo model) |
||
|
(3) |
Drain plug |
(9) |
Oil level gauge (Turbo model) |
Tightening torque:N·m (kgf-m, ft-lb) | |
|
(4) |
Gasket |
(10) |
Oil seal (Dual-range) |
T1: |
44 (4.5, 32.5) (Aluminum gasket) |
|
(5) |
Plug |
(11) |
Transmission case ASSY (Dual-range) |
70 (7.1, 51.6) (Copper gasket) | |
|
(6) |
Clamp |
(12) |
High-low cable bracket A (Dual-range) |
T2: |
60 (6.1, 44.3) |
Transmission case tightening torque
|
|
Bolt No. |
Bolt size mm |
Tightening torque: N·m (kgf-m, ft-lb) |
|
(5) — (15) |
8 |
25 (2.5, 18.4) | |
|
(1) — (4) (16), (17) |
10 |
39 (4.0, 28.8) |
AWD model
|
(1) |
Drive pinion shaft |
(15) |
Ball detent (excluding 1.5 L models) |
(29) |
Thrust bearing |
|
(2) |
Roller bearing |
(16) |
Reverse driven gear (excluding 1.5 L models) |
(30) |
Differential bevel gear sleeve |
|
(3) |
Washer |
(17) |
Outer baulk ring |
(31) |
Washer |
|
(4) |
Thrust bearing |
(18) |
Synchro cone |
(32) |
Lock washer |
|
(5) |
Needle bearing |
(19) |
Inner baulk ring |
(33) |
Lock nut |
|
(6) |
Driven shaft |
(20) |
2nd driven gear |
(34) |
Inner baulk ring (excluding 1.5 L models) |
|
(7) |
Key |
(21) |
2nd driven gear bushing |
(35) |
Synchro cone (excluding 1.5 L models) |
|
(8) |
Woodruff key |
(22) |
3rd-4th driven gear |
(36) |
Outer baulk ring (excluding 1.5 L models) |
|
(9) |
Drive pinion collar |
(23) |
Driven pinion shim |
||
|
(10) |
Needle bearing |
(24) |
Roller bearing |
Tightening torque:N·m (kgf-m, ft-lb) | |
|
(11) |
1st driven gear |
(25) |
5th driven gear |
T1: |
30 (3.1, 22.1) |
|
(12) |
Baulk ring (1.5 L model) |
(26) |
Lock washer |
T2: |
120 (12.2, 88.5) |
|
(13) |
1st-2nd synchronizer hub (1.5 L model) |
(27) |
Lock nut |
T3: |
260 (26.5, 191.8) |
|
(14) |
Insert key (1.5 L model) |
(28) |
Adjusting washer |
||
FWD model
|
(1) |
Drive pinion shaft |
(10) |
Insert key |
(19) |
Ball bearing |
|
(2) |
Key |
(11) |
Reverse driven gear |
(20) |
5th driven gear |
|
(3) |
Woodruff key |
(12) |
Outer baulk ring |
(21) |
Lock washer |
|
(4) |
Roller bearing |
(13) |
Synchro cone |
(22) |
Lock nut |
|
(5) |
1st gear thrust plate |
(14) |
Inner baulk ring |
||
|
(6) |
1st gear bushing |
(15) |
2nd driven gear |
Tightening torque:N·m (kgf-m, ft-lb) | |
|
(7) |
1st driven gear |
(16) |
2nd gear bushing |
T1: |
30 (3.1, 22.1) |
|
(8) |
1st baulk ring |
(17) |
3rd-4th driven gear |
T2: |
120 (12.2, 88.5) |
|
(9) |
1st-2nd synchronizer hub |
(18) |
Driven pinion shim |
||
3. MAIN SHAFT ASSY FOR SINGLE-RANGE
|
(1) |
Oil seal |
(14) |
4th drive gear |
(27) |
Baulk lever |
|
(2) |
Needle bearing |
(15) |
4th needle bearing race |
(28) |
5th hub & sleeve No. 2 |
|
(3) |
Transmission main shaft |
(16) |
Needle bearing |
(29) |
Lock washer |
|
(4) |
Needle bearing |
(17) |
4th gear thrust washer |
(30) |
Lock nut |
|
(5) |
3rd drive gear |
(18) |
Ball bearing (1.5 L model) |
(31) |
Straight pin |
|
(6) |
3rd baulk ring (1.5 L model) |
(19) |
Double-row tapered roller bearing (excluding 1.5 L models) |
(32) |
Reverse idler gear shaft |
|
(7) |
Inner baulk ring (excluding 1.5 L models) |
(20) |
5th gear thrust washer (1.5 L model) |
(33) |
Washer |
|
(8) |
3rd synchro cone (excluding 1.5 L models) |
(21) |
5th needle bearing race (1.5 L model) |
(34) |
Reverse idler gear |
|
(9) |
Outer baulk ring (excluding 1.5 L models) |
(22) |
5th needle bearing race (excluding 1.5 L models) |
(35) |
Washer |
|
(10) |
3rd-4th coupling sleeve |
(23) |
Needle bearing |
||
|
(11) |
3rd-4th synchronizer hub |
(24) |
Main shaft rear plate |
Tightening torque:N·m (kgf-m, ft-lb) | |
|
(12) |
3rd-4th shifting insert key |
(25) |
5th drive gear |
T: |
120 (12.2, 88.5) |
|
(13) |
4th baulk ring |
(26) |
5th baulk ring |
||
4. MAIN SHAFT ASSEMBLY FOR DUAL-RANGE
|
(1) |
O-ring |
(28) |
Friction damper |
(55) |
5th hub & sleeve No. 2 |
|
(2) |
High-low countershaft |
(29) |
Input low gear |
(56) |
Lock washer |
|
(3) |
Knock pin |
(30) |
Needle bearing |
(57) |
Lock nut |
|
(4) |
High-low counter washer |
(31) |
Input low gear spacer |
(58) |
Reverse idler gear shaft |
|
(5) |
Counter gear |
(32) |
Ball |
(59) |
Straight pin |
|
(6) |
Needle bearing |
(33) |
Main shaft |
(60) |
Reverse idler gear |
|
(7) |
Counter gear collar |
(34) |
Needle bearing |
(61) |
Washer |
|
(8) |
Snap ring (Outer-19) |
(35) |
3rd drive gear |
(62) |
Straight pin |
|
(9) |
Input shaft holder |
(36) |
Inner baulk ring (2.0 L model) |
(63) |
High-low shifter lever |
|
(10) |
Input shaft shim |
(37) |
Synchro cone (2.0 L model) |
(64) |
High-low shifter shaft |
|
(11) |
Oil seal |
(38) |
Outer baulk ring (2.0 L model) |
(65) |
Low switch |
|
(12) |
O-ring |
(39) |
3rd-4th coupling sleeve |
(66) |
Gasket |
|
(13) |
Snap ring (Outer-28) |
(40) |
3rd-4th synchronizer hub |
(67) |
Straight pin |
|
(14) |
Oil squeeze |
(41) |
3rd-4th shifting insert key |
(68) |
High-low shifter fork |
|
(15) |
Straight pin |
(42) |
4th baulk ring |
(69) |
High-low shifter piece |
|
(16) |
Snap ring (Outer-28) |
(43) |
4th drive gear |
(70) |
Ball |
|
(17) |
Ball bearing |
(44) |
4th needle bearing race |
(71) |
Spring |
|
(18) |
Snap ring (Inner 68) |
(45) |
Needle bearing |
(72) |
Gasket |
|
(19) |
Input shaft |
(46) |
4th gear thrust washer |
(73) |
Plug |
|
(20) |
Needle bearing |
(47) |
Ball bearing |
(74) |
Baulk ring (1.5 L model) |
|
(21) |
Snap ring (Outer-25) |
(48) |
5th gear thrust washer |
(75) |
Washer |
|
(22) |
High-low baulk ring |
(49) |
5th needle bearing race |
||
|
(23) |
High-low cup ring sleeve |
(50) |
Needle bearing |
Tightening torque:N·m (kgf-m, ft-lb) | |
|
(24) |
High-low synchronizer spring |
(51) |
Main shaft rear plate |
T1: |
9.75 (1.0, 7.2) |
|
(25) |
High-low synchronizer hub |
(52) |
5th drive gear |
T2: |
20 (2.0, 14.8) |
|
(26) |
Shifting insert key |
(53) |
5th baulk ring |
T3: |
32.3 (3.3, 23.8) |
|
(27) |
High-low baulk ring |
(54) |
Baulk lever |
T4: |
120 (12.2, 88.5) |
5. SHIFTER FORK AND SHIFTER ROD
|
(1) |
Shifter arm |
(8) |
Ball |
(15) |
Spring |
|
(2) |
5th shifter fork |
(9) |
3rd-4th fork rod |
(16) |
Snap ring (Outer) |
|
(3) |
Straight pin |
(10) |
Interlock plunger |
(17) |
Reverse fork rod arm |
|
(4) |
Reverse fork rod |
(11) |
1st-2nd fork rod |
(18) |
Reverse shifter lever |
|
(5) |
Checking ball plug |
(12) |
3rd-4th shifter fork |
||
|
(6) |
Gasket |
(13) |
1st-2nd shifter fork |
Tightening torque:N·m (kgf-m, ft-lb) | |
|
(7) |
Checking ball spring |
(14) |
Ball |
T: |
20 (2.0, 14.8) |
6. TRANSFER CASE AND EXTENSION
|
(1) |
Oil guide |
(16) |
Return spring |
(31) |
Transfer drive gear |
|
(2) |
Gasket |
(17) |
O-ring |
(32) |
Ball bearing |
|
(3) |
Transfer case |
(18) |
Adjusting select shim |
(33) |
Extension case |
|
(4) |
Ball |
(19) |
Reverse check sleeve |
(34) |
Oil seal |
|
(5) |
Reverse accent spring |
(20) |
Gasket |
(35) |
Dust cover |
|
(6) |
Gasket |
(21) |
Neutral position switch |
(36) |
Shift bracket |
|
(7) |
Plug |
(22) |
Gasket |
(37) |
Snap ring |
|
(8) |
Oil seal |
(23) |
Back-up light switch |
||
|
(9) |
Snap ring (Inner) |
(24) |
Roller bearing |
Tightening torque:N·m (kgf-m, ft-lb) | |
|
(10) |
Reverse check plate |
(25) |
Transfer driven gear |
T1: |
6.4 (0.7, 4.7) |
|
(11) |
Reverse check spring |
(26) |
Roller bearing |
T2: |
9.75 (1.0, 7.2) |
|
(12) |
Reverse return spring |
(27) |
Adjusting washer |
T3: |
24.5 (2.5, 18.1) |
|
(13) |
Reverse check cam |
(28) |
Ball bearing |
T4: |
26 (2.7, 19.2) |
|
(14) |
Reverse accent shaft |
(29) |
Center differential |
T5: |
32.3 (3.3, 23.8) |
|
(15) |
Return spring cap |
(30) |
Adjusting washer |
T6: |
40 (4.1, 29.5) |
|
(1) |
Oil guide |
(11) |
Snap ring |
(21) |
Reverse check sleeve |
|
(2) |
Gasket |
(12) |
Reverse check plate |
(22) |
Gasket |
|
(3) |
Rear case |
(13) |
Reverse check spring |
(23) |
Back-up light switch |
|
(4) |
Oil seal |
(14) |
Reverse return spring |
||
|
(5) |
Ball |
(15) |
Reverse check cam |
Tightening torque:N·m (kgf-m, ft-lb) | |
|
(6) |
Reverse accent spring |
(16) |
Reverse accent shaft |
T1: |
6.4 (0.7, 4.7) |
|
(7) |
Washer |
(17) |
Return spring cap |
T2: |
9.75 (1.0, 7.2) |
|
(8) |
Plug |
(18) |
Return spring |
T3: |
24.5 (2.5, 18.1) |
|
(9) |
Gasket |
(19) |
O-ring |
T4: |
32.3 (3.3, 23.8) |
|
(10) |
Neutral position switch |
(20) |
Adjuster select shim |
||
|
(1) |
Drive pinion shaft |
(7) |
Differential bevel pinion |
(13) |
Retainer lock plate |
|
(2) |
Hypoid driven gear |
(8) |
Roller bearing |
||
|
(3) |
Pinion shaft |
(9) |
Differential case |
Tightening torque:N·m (kgf-m, ft-lb) | |
|
(4) |
Straight pin |
(10) |
Oil seal |
T1: |
25 (2.5, 18.4) |
|
(5) |
Washer |
(11) |
Differential side retainer |
T2: |
62 (6.3, 45.7) |
|
(6) |
Differential bevel gear |
(12) |
O-ring |
||
|
(1) |
Pitching stopper |
(7) |
Cushion rubber |
Tightening torque:N·m (kgf-m, ft-lb) | |
|
(2) |
Spacer |
(8) |
Center crossmember |
T1: |
35 (3.6, 25.8) |
|
(3) |
Cushion rubber |
(9) |
Rear plate |
T2: |
50 (5.1, 36.9) |
|
(4) |
Front plate |
(10) |
Front crossmember |
T3: |
58 (5.9, 42.8) |
|
(5) |
Transmission cushion rubber (AWD model) |
(11) |
Rear cushion rubber |
T4: |
70 (7.1, 51.6) |
|
(6) |
Rear crossmember |
(12) |
Transmission cushion rubber (FWD model) |
T5: |
140 (14.3, 103.3) |