Page 457 of 2248

B: INSPECTION
1) Check the drive plate facing for wear and damage.
2) Check the snap ring for wear, return spring for perma-
nent set and breakage, and spring retainer for deformation.
3) Check the lathe cut ring for damage.
G3M0498
C: ASSEMBLY
1) Install the lathe cut seal ring to the I.D./O.D. of the
transfer clutch piston.
G3M0499
2) Install piston.
(1) Connect piston to rear drive shaft (until it reaches
hole in valve body).
(2) Install spring retainer to piston.
(3) Using ST1, ST2 and ST3, attach transfer piston
seal to ST2.
ST1 499247400 INSTALLER
ST2 499257400 PISTON GUIDE
ST3 498267400 TABLE
CAUTION:
Be careful not to tilt transfer piston seal.
G3M0500
(4) Place ST3 onto rear drive shaft so that spring can
be inserted into hole in transfer piston seal.
(5) Attach ST2 to rear drive shaft. Using ST1, press
into place.
ST1 499247400 INSTALLER
ST2 499257300 SNAP RING OUTER GUIDE
ST3 499257400 PISTON GUIDE
CAUTION:
Do not allow lip of transfer piston seal to fold back.
11 0
3-2SERVICE PROCEDURE
15. Transfer Clutch
Page 458 of 2248
G3M0501
3) Install the driven plates, drive plates, and pressure
plate, and secure with a snap ring with ST1, ST2 and a
press.
ST1 398673600 COMPRESSOR
ST2 498627000 SEAT
G3M0502
4) Apply compressed air to see if the assembled parts
move smoothly.
G3M0503
5) Check the clearance.
Standard value:
0.2—0.6 mm (0.008—0.024 in)
Allowable limit:
1.6 mm (0.063 in)
If the clearance is not within the specified range, select a
proper pressure plate.
NOTE:
Before measuring clearance, place the same thickness of
shim on both sides to prevent pressure plate from tilting.
Available pressure platesPart No. Thickness mm (in)
31593AA151
31593AA161
31593AA171
31593AA1813.3 (0.130)
3.7 (0.146)
4.1 (0.161)
4.5 (0.177)
G3M0505
6) Press-fit the ball bearing with ST.
ST 899580100 INSTALLER
111
3-2SERVICE PROCEDURE
15. Transfer Clutch
Page 459 of 2248
G3M0505
7) Coat the seal ring with vaseline, and install it in the seal
ring groove of the shaft.
CAUTION:
Do not expand the seal ring excessively when install-
ing.
ST 899580100 INSTALLER
G3M0913
16. Transfer Valve Body
A: DISASSEMBLY
1) Remove the plate. Then remove the spring and pilot
valve together.
2) Remove the straight pin and pry out the plug with a
screwdriver. Then extract the spring and transfer clutch
valve together.
CAUTION:
Be careful not to damage the valve and valve body.
B: INSPECTION
Check each component for harmful cuts, damage, or other
faults.
C: ASSEMBLY
To assemble, reverse the removal sequence.
NOTE:
Make sure the valve slides smoothly after assembling.
11 2
3-2SERVICE PROCEDURE
15. Transfer Clutch - 16. Transfer Valve Body
Page 460 of 2248
G3M0505
7) Coat the seal ring with vaseline, and install it in the seal
ring groove of the shaft.
CAUTION:
Do not expand the seal ring excessively when install-
ing.
ST 899580100 INSTALLER
G3M0913
16. Transfer Valve Body
A: DISASSEMBLY
1) Remove the plate. Then remove the spring and pilot
valve together.
2) Remove the straight pin and pry out the plug with a
screwdriver. Then extract the spring and transfer clutch
valve together.
CAUTION:
Be careful not to damage the valve and valve body.
B: INSPECTION
Check each component for harmful cuts, damage, or other
faults.
C: ASSEMBLY
To assemble, reverse the removal sequence.
NOTE:
Make sure the valve slides smoothly after assembling.
11 2
3-2SERVICE PROCEDURE
15. Transfer Clutch - 16. Transfer Valve Body
Page 461 of 2248
G6M0095
17. Transmission Control Module
A: REMOVAL
1) Disconnect battery ground cable.
B3M0377A
2) Remove lower cover and then disconnect connector.
OBD0040
3) Remove TCM from steering support beam.
4) Disconnect connectors form TCM
1.
OBD0040
B: INSTALLATION
1) Connect connectors to TCM1.
2) Install TCM to steering support beam.
Tightening torque:
7.4±2.0 N⋅m (0.75±0.2 kg-m, 5.4±1.4 ft-lb)
3) Installing procedure hereafter is in the reverse order of
removal.
11 3
3-2SERVICE PROCEDURE
17. Transmission Control Module
Page 462 of 2248
1. Manual Transmission
1. AWD MODEL
B3M0005B
1Gear shift knob
2Console boot
3Boot plate
4Gear shift lever
5Bush
6Spacer
7Locking wire
8Boot
9Snap ring
10O-ring
11Bush
12Cushion rubber
13Boss
14Joint
15Rod
16Bracket
17Spring
18Washer
19Stay
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 4.4±1.5 (0.45±0.15, 3.3±1.1)
T2: 5 (0.51, 3.7)
T3: 12±3 (1.2±0.3, 8.7±2.2)
T4: 18±5 (1.8±0.5, 13.0±3.6)
T5: 24.5±2 (2.50±0.20, 18.07±1.48)
2
3-3COMPONENT PARTS
1. Manual Transmission
Page 463 of 2248
2. FWD MODEL
B3M0006B
1Gear shift knob
2Console boot
3Boot plate
4Gear shift lever
5Bush
6Spacer
7Locking wire
8Boot
9Snap ring
10O-ring
11Bush
12Cushion rubber
13Boss
14Joint
15Rod
16Bracket
17Spring
18Stay
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 4.4±1.5 (0.45±0.15, 3.3±1.1)
T2: 5 (0.51, 3.7)
T3: 12±3 (1.2±0.3, 8.7±2.2)
T4: 18±5 (1.8±0.5, 13.0±3.6)
T5: 29±5 (3.0±0.5, 21.7±3.6)
3
3-3COMPONENT PARTS
1. Manual Transmission
Page 464 of 2248
2. Automatic Transmission
1. LHD MODEL
B3M0415A
1Button
2Spring
3Grip
4Indicator cover
5“P” position switch
6Indicator light bulb
7Shift-lock solenoid
8Plate
9Packing
10Outer cable
11Nut
12Nut
13Inner cable
14Clip
15Rod
16Selector lever
17Lock plate
18Detention spring
19Pin
20Spacer
21Washer
22Boot
23Spacer
24Snap pin
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 2.0±0.7 (0.2±0.07, 1.4±0.5)
T2: 4.4±1.5 (0.45±0.15, 3.3±1.1)
T3: 12±3 (1.2±0.3, 8.7±2.2)
T4: 18±5 (1.8±0.5, 13.0±3.6)
4
3-3COMPONENT PARTS
2. Automatic Transmission