1. Install the plunger and check ball spring to transmission cover.
Tightening torque:
25 N·m (2.5 kgf-m, 18.4 ft-lb)
|
(A) |
Plunger |
|
(B) |
Checking ball spring |
|
(C) |
Transmission cover |
|
(D) |
Seal ring |
|
(E) |
Seal bolt |
2. Using the ST, install the oil seal to the transfer case.
NOTE:
• Use a new oil seal.
• The illustration shows the oil seal of selector lever COMPL. Perform the same procedures for installing the shifter arm No. 2.
• Apply transmission gear oil to the oil seal lips.
| ST 18657AA000 | INSTALLER |
Press-fit depth of oil seal:
−1 mm (−0.04 in) from the end of transfer case
3. Insert the shifter arm into selector arm, then fix with a spring pin using the ST.
NOTE:
Use new spring pin.
| ST 398791700 | SPRING PIN REMOVER 2 |
|
(A) |
Shifter arm |
|
(B) |
Selector arm |
|
(C) |
Spring pin |
4. Install the shifter arm No. 2, washers and thrust bearing to transfer case.
|
(A) |
Shifter arm No. 2 |
|
(B) |
Washer |
|
(C) |
Thrust bearing |
5. Install the shifter arm collar and neutral set spring to transfer case.
Tightening torque:
6.4 N·m (0.7 kgf-m, 4.7 ft-lb)
6. Install the selector arm No. 2 to neutral set spring.
|
(A) |
Selector arm No. 2 |
|
(B) |
Neutral set spring |
7. Insert the selector lever COMPL into selector arm No. 2, then fix with a spring pin using the ST.
NOTE:
Use new spring pin.
| ST 398791700 | SPRING PIN REMOVER 2 |
|
(A) |
Selector lever COMPL |
|
(B) |
Selector arm No. 2 |
|
(C) |
Spring pin |
8. Insert a new straight pin.
|
(A) |
Selector lever COMPL |
|
(B) |
Straight pin |
9. Apply a proper amount of liquid gasket to the transmission cover mating surface.
Liquid gasket:
THREE BOND 1215 (Part No. 004403007) or equivalent
10. Install the transmission cover to transfer case.
Tightening torque:
25 N·m (2.5 kgf-m, 18.4 ft-lb)
|
(A) |
Transmission cover |
11. Install the extension assembly to the transfer case. 
12. Install the transfer case and the extension case assembly.
13. Install the back-up light switch and the neutral position switch.
14. Install the manual transmission assembly to the vehicle.