Page 761 of 2890

9. CENTER DIFFERENTIAL (AWD Model)
Snap ring (Inner-110) to center differential case clearance
0—0.15 mm (0—0.0059 in)
Snap ring (Inner-110)
Part No. Thickness mm (in)
805100061 2.10 (0.0827)
805100062 2.21 (0.0870)
805100063 2.32 (0.0913)
Backlash adjustment axial movement
0.62—0.86 mm (0.0244—0.0339 in)
Adjusting washer (45 x 62 x t)
Part No. Thickness mm (in)
803045041 1.60 (0.0630)
803045042 1.80 (0.0709)
803045043 2.00 (0.0787)
803045044 2.20 (0.0866)
803045045 2.40 (0.0945)
10. FRONT DIFFERENTIAL
Bevel gear to pinion backlash
0.13—0.18 mm (0.0051—0.0071 in)
Washer (38.1 x 50 x t)
Part No.Thickness
mm (in)Part No.Thickness
mm (in)
8030380210.925—
0.950
(0.0364—
0.0374)8030380231.025—
1.050
(0.0404—
0.0413)
8030380220.975—
1.000
(0.0384—
0.0394)
Pinion shaft to axle drive shaft clearance
0—0.2 mm (0—0.008 in)
Snap ring (Outer-28)
Part No.Thickness
mm (in)Part No.Thickness
mm (in)
805028011 1.05 (0.0413) 805028012 1.20 (0.0472)
5
3-1SPECIFICATIONS AND SERVICE DATA
1. Manual Transmission and Differential
Page 762 of 2890
1. Transfer Case and Extension (AWD
Model)
B3M0326A
1Transfer cover
2Cover gasket
3Oil seal
4Gasket
5Neutral switch
6Back-up light switch
7Transfer case
8Gasket
9Oil guide
10Ball
11Reverse accent spring
12Gasket
13Plug
14Snap ring (Inner)
15Reverse check plate
16Reverse check spring
17Reverse return spring
18Reverse check cam
19Reverse accent shaft
20O-ring
21Adjusting select shim
22Reverse check sleeve
23Adjusting washer
24Ball bearing
25Transfer driven gear
26Ball bearing
27Oil seal
28Shift bracket
29Extension cover
30Gasket
31Snap ring (Outer-30)
32Gasket
33Ball bearing
34Snap ring (Inner-72)
35Transfer drive gear
36Extension
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 5±1 (0.5±0.1, 3.6±0.7)
T2: 10±1 (1.0±0.1, 7.2±0.7)
T3: 15.7±1.5
(1.6±0.15, 11.6±1.1)
T4: 25±2 (2.5±0.2, 18.1±1.4)
T5: 37±3 (3.8±0.3, 27.5±2.2)
6
3-1COMPONENT PARTS
1. Transfer Case and Extension (AWD Model)
Page 763 of 2890
2. Rear Case (FWD Model)
G3M0265
1Rear case
2Case gasket
3Back-up light switch
4Neutral switch
5Reverse check sleeve ASSY
6Gasket
7Adjusting shim
8O-ring
9Oil seal
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 6.4±0.5 (0.65±0.05, 4.7±0.4)
T2: 25±2 (2.5±0.2, 18.1±1.4)
7
3-1COMPONENT PARTS
2. Rear Case (FWD Model)
Page 764 of 2890
3. Transmission Case
B3M0327A
1Transmission case ASSY
2Gasket
3Drain plug
4Snap ring (Outer)
5Speedometer driven gear
6Washer
7Speedometer shaft
8Snap ring (Outer)
9Oil seal
10Oil level gauge
11Pitching stopper bracket
12Clamp
13Clip
Tightening torque: N⋅m (kg-m, ft-lb)
T: 44±3 (4.5±0.3, 32.5±2.2)
Size All models Torque
8 mm bolt
5—15
25±2 N⋅m
(2.5±0.2 kg-m,
18.1±1.4 ft-lb)
10 mm bolt
1—4
16—17
39±2 N⋅m
(4.0±0.2 kg-m,
28.9±1.4 ft-lb)
8
3-1COMPONENT PARTS
3. Transmission Case
Page 765 of 2890
4. Shifter Fork and Shifter Rod
B3M0338A
1Plug
2Gasket
3Reverse accent spring
4Ball
5Snap ring (Inner)
6Reverse check plate
7Reverse check spring
8Reverse return spring
9Reverse check cam
10Reverse accent shaft
11O-ring
12Adjusting select shim
13Reverse check sleeve
14Selector arm (AWD model)
15Shifter arm (AWD model)
16Reverse shifter lever
17Reverse fork rod arm
18Snap ring (Outer)
19Spring
20Ball
213rd-4th shifter fork
221st-2nd shifter fork
23Straight pin
24Reverse fork rod
255th shifter fork
26Interlock plunger
273rd-4th fork rod
281st-2nd fork rod
29Ball
30Checking ball spring
31Gasket
32Checking ball plug
33Shifter arm (FWD model)
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 6.4±0.5 (0.65±0.05, 4.7±0.4)
T2: 10±1 (1.0±0.1, 7.2±0.7)
T3: 19.6±1.5
(2.00±0.15, 14.5±1.1)
9
3-1COMPONENT PARTS
4. Shifter Fork and Shifter Rod
Page 766 of 2890
5. Drive Pinion Assembly
1. AWD MODEL
G3M0510
1Drive pinion shaft
2Roller bearing
3Washer
4Thrust bearing
5Needle bearing
6Key
7Driven shaft
8Woodruff key
9Drive pinion collar
10Snap ring (Outer)
11Washer
12Sub gear
131st driven gear
14Baulk ring
15Spring
161st-2nd synchronizer hub
17Insert
18Reverse driven gear
192nd driven gear
202nd driven gear bush
213rd-4th driven gear
22Driven pinion shim
23Roller bearing
245th driven gear
25Lock washer
26Lock nut
27Washer
28Differential bevel gear sleeve
29Washer
30Lock washer
31Lock nut
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 29±3 (3.0±0.3, 21.7±2.2)
T2: 118±8 (12.0±0.8, 86.8±5.8)
T3: 245±10 (25.0±1.0, 181±7)
10
3-1COMPONENT PARTS
5. Drive Pinion Assembly
Page 767 of 2890
2. FWD MODEL
B3M0339A
1Drive pinion shaft
2Key
3Woodruff key
4Roller bearing
51st gear thrust plate
6Snap ring (Outer)
7Washer
81st sub gear
91st gear bushing
101st driven gear
111st-2nd baulk ring
121st-2nd synchronizer spring
131st-2nd synchronizer hub
141st-2nd shifting insert
15Reverse driven gear
162nd driven gear
172nd gear bushing
182nd sub gear
193rd-4th driven gear
20Drive pinion shim
21Ball bearing
225th driven gear
23Lock washer
24Lock nut
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 29±3 (3.0±0.3, 22±2)
T2: 118±6 (12.0±0.6, 86.8±4.3)
11
3-1COMPONENT PARTS
5. Drive Pinion Assembly
Page 768 of 2890
6. Main Shaft Assembly
G3M0841
1Oil seal
2Needle bearing
3Transmission main shaft
44th needle bearing race
5Needle bearing
63rd drive gear
7Baulk ring
8Synchronizer spring
9Synchronizer hub
10Coupling sleeve
11Shifting insert
124th drive gear
134th gear thrust washer
14Ball bearing
155th gear thrust washer
165th needle bearing race
17Main shaft rear plate
185th drive gear
19Insert stopper plate
20Lock washer
21Lock nut
22Reverse idler gear shaft
23Straight pin
24Reverse idler gear
25Washer
Tightening torque: N⋅m (kg-m, ft-lb)
T: 118±6 (12.0±0.6, 86.8±4.3)
12
3-1COMPONENT PARTS
6. Main Shaft Assembly