1. Install the plunger and check ball spring to transmission cover.
NOTE:
Use a new seal ring.
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 needle bearing to the transfer case.
NOTE:
• Use a new needle bearing.
• If the press-fit depth exceeds the service limit, replace with a new needle bearing.
| ST1 18763AA000 | COMPRESSOR SHAFT |
| ST2 498277200 | STOPPER SET |
Press-fit depth of needle bearing:
A: 8.5±0.2 mm (0.33±0.01 in) from the end of transfer case
B: 0.2±0.2 mm (0.01±0.01 in) from the end of transfer case
3. Set ST1, ST2 and transfer case to a press.
NOTE:
• Set the ST2 under ST1.
• Set the transfer case so that the hole for shifter arm is positioned vertically.
| ST1 498267300 | CYLINDER HEAD TABLE |
| ST2 498267200 | CYLINDER HEAD TABLE |
4. Using the ST, install the roller bearing to the transfer case.
NOTE:
• Use a new bearing.
• Gradually perform the press-fit operation while measuring the press-fit depth.
• If the press-fit depth exceeds the service limit, replace with a new bearing.
| ST 899864100 | REMOVER |
Press-fit depth of roller bearing:
A: 5.1±0.2 mm (0.20±0.01 in) from the finished surface of transfer case
5. Flip over the transfer case, and set an iron plate between transfer case and ST.
NOTE:
• Insert the iron plate which is thicker than the exposed length of the transfer case knock pin between the ST and transfer case.
• Set the parts while taking care that the transfer case knock pin and the roller bearing do not ride over the iron plate.
6. Using the ST, install the roller bearing to the transfer case.
NOTE:
• Use a new bearing.
• Gradually perform the press-fit operation while measuring the press-fit depth.
• If the press-fit depth exceeds the service limit, replace with a new bearing.
| ST 899864100 | REMOVER |
Press-fit depth of roller bearing:
A: 0±0.2 mm (0±0.01 in) from the end of transfer case
7. 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±0.2 mm (0.04±0.01 in) from the end of transfer case
8. Insert the shifter arm into the selector arm, and fix with a spring pin.
NOTE:
Use new spring pin.
| ST 398791700 | SPRING PIN REMOVER 2 |
|
(A) |
Shifter arm |
|
(B) |
Selector arm |
|
(C) |
Spring pin |
9. Install the shifter arm No. 2, washers and thrust bearing to transfer case.
|
(A) |
Shifter arm No. 2 |
|
(B) |
Washer |
|
(C) |
Thrust bearing |
10. 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)
11. Install the selector arm No. 2 to neutral set spring.
|
(A) |
Selector arm No. 2 |
|
(B) |
Neutral set spring |
12. Insert the selector lever COMPL into the selector arm No. 2, and fix with a spring pin.
NOTE:
Use new spring pin.
| ST 398791700 | SPRING PIN REMOVER 2 |
|
(A) |
Selector lever COMPL |
|
(B) |
Selector arm No. 2 |
|
(C) |
Spring pin |
13. Insert a new straight pin.
|
(A) |
Selector lever COMPL |
|
(B) |
Straight pin |
14. Apply liquid gasket seamlessly to the mating surface of transmission cover.
Liquid gasket:
THREE BOND 1215 (Part No. 004403007) or equivalent
15. Install the transmission cover to transfer case.
Tightening torque:
25 N·m (2.5 kgf-m, 18.4 ft-lb)
|
(A) |
Transmission cover |
16. Attach the extension assembly to the transfer case. 
17. Install the transfer case and the extension case assembly.
18. Install the back-up light switch and the neutral position switch.
19. Install the manual transmission assembly to the vehicle.