Transfer Assembly: Reassembly

Using a feeler gauge, measure the clearance between the shift fork No. 2 and clutch sleeve.

Standard clearance: 

0.10 - 0.40 mm (0.0039 - 0.0157 in.) 

Maximum clearance: 

0.40 mm (0.0157 in.) 

Fig 1: Measuring Clearance Between Shift Fork And Clutch Sleeve

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Using SST and a press, install the bearing race.

SST 09316-60011 (09316-00011, 09316-00031), 09950-60020 (09951-00890)

Fig 2: Installing Output Shaft Bearing Race

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Using SST and a press, install the bearing race.

SST 09316-60011 (09316-00011, 09316-00031), 09950-60020 (09951-00790)

Fig 3: Installing Idler Gear Bearing Race

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Install the oil receiver and bolt.

Torque: 12 N.m (120 kgf.cm, 9 ft.lbf) 

Fig 4: Installing Oil Receiver And Bolt

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1. Install the shift inner lever, washer and outer lever to the front case.
2. Using a pin punch, hammer and socket wrench, tap in the lever lock pin.
3. Install the washer and nut to the shift outer lever.

Torque: 12 N.m (120 kgf.cm, 9 ft.lbf) 

Fig 5: Tapping In Lever Lock Pin

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1. Assemble the shift fork No. 1 and shift fork No. 1 shaft.
2. Using a pin punch and hammer, drive in the slotted spring pin.
   Fig 6: Driving In Slotted Spring Pin

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1. Apply FIPG to the front case.

   FIPG: 

   Part No. 08826-00090, THREE BOND 1281 or equivalent 

2. Assemble the front case and rear case.
   Fig 8: Applying FIPG To Front Case

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3. Apply liquid sealer to the "A" bolt threads.

   Sealant: 

   Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

4. Install the 8 bolts.

   Torque: 37 N.m (380 kgf.cm, 27 ft.lbf) 

   Fig 9: Installing Bolts

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Using a snap ring expander, install the snap ring to the rear case.

Fig 10: Installing Snap Ring Using Snap Ring Expander

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1. Apply FIPG to the rear case.

   FIPG: 

   Part No. 08826-00090, THREE BOND 1281 or equivalent 

2. Install the case cover.
   Fig 11: Applying FIPG To Rear Case

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3. Apply liquid sealer to the bolt threads.

   Sealant: 

   Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

4. Install the 5 bolts.

   Torque: 37 N.m (380 kgf.cm, 27 ft.lbf) 

   Fig 12: Installing Bolts

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Install the oil strainer and 2 bolts.

Torque: 4.9 N.m (50 kgf.cm, 43 in.lbf) 

Fig 13: Installing Oil Strainer To Rear Case

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1. Using vernier calipers, measure dimension "A".
2. Lightly hole down the bearing outer race in the thrust direction to eliminate any looseness before making the measurement.
   Fig 14: Measuring Dimension A Using Vernier Calipers

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3. Using a steel straight edge and feeler gauge, measure the clearance of dimension "B".
4. Calculate the required thickness of the adjusting shim.

   Thickness: Dimension "A" + Dimension "B" + [0.022 - 0.049 mm, (0.0009 - 0.0019 In.)] 

   Fig 15: Measuring Clearance Of Dimension B Using Steel Straight Edge And Feeler Gauge

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5. From the following table, select a shim so that its thickness is within the range of the calculation.
   Fig 16: Shim Specification Table

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1. Using a steel straight edge and feeler gauge, measure the clearance of dimension "C".
2. Lightly hold down the bearing outer race in the thrust direction to eliminate any looseness before making the measurement.
   Fig 17: Measuring Clearance Of Dimension C

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3. Using a steel straight edge and vernier calipers with depth gauge, measure dimension "D".
4. Dimension "D" is the straight edge thickness (Dimension "F") subtracted from dimension "E" in the illustration to the left.

   Dimension "D": Dimension "E" - Dimension "F" 

   Fig 18: Measuring Clearance Of Dimension D, F And E Using Steel Straight Edge And Feeler Gauge

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5. Using a steel straight edge and vernier calipers with depth gauge, measure dimension "G".
6. Dimension "G" is the straight edge thickness (Dimension "F") subtracted from Dimension "H".

   Dimension "G": Dimension "H" - Dimension "F" 

7. Calculate the required thickness of the adjusting shim.

   Thickness: Dimension "G" - (Dimension "D" - Dimension "C") + [0.014 ~ 0.039 mm, (0.0006 ~ 0.0015 in-)] 

   Fig 19: Measuring Clearance Of Dimension G Using Steel Straight Edge And Feeler Gauge

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8. From the following table, select a shim so that its thickness is within the range of the calculation.
   Fig 20: Shim Specification Table

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1. Apply FIPG to the rear extension housing.

   FIPG: 

   Part No. 08826-00090, THREE BOND 1281 or equivalent 

   Fig 21: Applying FIPG To Rear Extension Housing

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2. Install the rear extension housing and 9 bolts.

   Torque: 37 N.m (380 kgf.cm, 27 ft.lbf) 

1. Install the shift fork No. 2 to the shift fork No. 2 shaft.
2. Install the 3 snap rings to the shift fork No. 2 shaft.
   Fig 22: Installing Rear Extension Housing And 9 Bolts

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HINT:

Make sure to install the clutch sleeve in the correct direction.

Fig 23: Install Clutch Sleeve With Shift Fork No. 2 Shaft And Shift Fork No. 2

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1. Apply FIPG to the front extension housing.

   FIPG: 

   Part No. 08826-00090, THREE BOND 1281 or equivalent 

   Fig 24: Applying FIPG To Front Extension Housing

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2. Install the front extension housing and 6 bolts.

   Torque: 37 N.m (380 kgf.cm, 27 ft.lbf) 

   HINT:

   Set the clutch sleeve in differential lock condition.

Install the 3 transfer indicator switches with 3 new gaskets.

Torque: 37 N.m (380 kgf.cm, 27 ft.lbf) 

Fig 25: Installing Front Extension Housing And Bolts

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1. Install the ball and spring.
2. Apply liquid sealer to the screw plug threads.

   Sealant: 

   Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

3. Using a torx socket wrench (T40), install the screw plug.

   Torque: 19 N.m (190 kgf.cm, 14 ft.lbf) 

   Fig 26: Installing Ball, Spring & Screw

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HINT:

Apply gear oil to the output gear.

Fig 27: Installing Output Gear To Front Case

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1. Apply FIPG to the motor actuator.

   FIPG: 

   Part No. 08826-00090, THREE BOND 1281 or equivalent 

   Fig 28: Applying FIPG To Motor Actuator

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   HINT:

   Set the motor actuator in differential lock condition.

   Fig 29: Setting Motor Actuator In Differential Lock Condition

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2. Install the motor actuator and 4 bolts.

   Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) 

   Fig 30: Installing Motor Actuator And 4 Bolts.

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Install the driven gear and bolt.

Torque: 11 N.m (115 kgf.cm, 8 ft.lbf)