Page 785 of 2890

CAUTION:
Be careful not to break O-ring when placing shim(s).
Adjustment shim
Part No. Thickness mm (in)
32190AA000 0.15 (0.0059)
32190AA010 0.30 (0.0118)
When shim is removed, the neutral position will move
closer to reverse; when shim is added, the neutral position
will move closer to 1st gear.
If shims alone cannot adjust the clearance, replace
reverse accent shaft and re-adjust.
Reverse accent shaft
Part No. Mark Remarks
32188AA040 1 Neutral position is closer to 1st gear.
32188AA011No mark
or 2Standard
32188AA050 3Neutral position is closer to reverse
gear.
B3M0054A
4) Reverse check plate5adjustment
Shift shifter arm to“5th”and then to reverse to see if
reverse check mechanism operates properly. Also check to
see if arm returns to neutral when released from the
reverse position. If arm does not return properly, replace
reverse check plate.
Reverse check plate
Part No.
A: No. AngleθRemarks
32189AA000 0 28°Arm stops closer to 5th
gear.
32189AA010 1 31°Arm stops closer to 5th
gear.
32189AA020 2 34°Arm stops in the center.
32189AA030 3 37°Arm stops closer to reverse
gear.
32189AA040 4 40°Arm stops closer to reverse
gear.
B3M0055A
5) Install transfer6cover and gasket.
6) Connect each connector
7.
29
3-1SERVICE PROCEDURE
2. Transfer Case and Extension (AWD Model)
Page 786 of 2890
3. Rear Case (FWD Model)
A: DISASSEMBLY
G3M0952
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: 25±2 (2.5±0.2, 18.1±1.4)
1) Remove rear case1.
2) Remove plug
2, spring3and reverse check ball4.
3) Remove neutral switch
5.
4) Pull out shifter arm
6.
5) Remove reverse check sleeve
7.
NOTE:
The disassembly procedure is the same as for AWD model.
B3M0056A
6) Remove back-up light switch8.
7) Remove oil seal
9.
CAUTION:
Do not reuse oil seal.
30
3-1SERVICE PROCEDURE
3. Rear Case (FWD Model)
Page 787 of 2890

B: ASSEMBLY
1) Assembly of rear case is in the reverse order of disas-
sembly.
G3M0952
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: 25±5 (2.5±0.5, 18.1±3.6)
2) Installation of shifter arm6
Install shifter arm into the partition from the front while
inserting selector arm into the opening in reverse check
sleeve. Pass shaft through hole in selector arm until its end
comes out of the rear of transmission case assembly.
CAUTION:
Apply a coat of gear oil to shifter arm. Also make sure
oil seal is positioned properly.
3) Adjustment of neutral position
NOTE:
After assembling and installing rear case, adjust neutral
position.
(1) Shift gear into 3rd gear position.
(2) Shifter arm turns lightly toward the 1st/2nd gear
side but heavily toward the reverse gear side because
of the function of the return spring, until arm contacts
the stopper.
(3) Make adjustment so that the heavy stroke (reverse
side) is a little more than the light stroke (1st/2nd side).
(4) To adjust, remove bolts holding reverse check
sleeve assembly to the case, move sleeve assembly
outward, and place adjustment shim (0 to 1 ea.)
between sleeve assembly and case to adjust the clear-
ance.
31
3-1SERVICE PROCEDURE
3. Rear Case (FWD Model)
Page 788 of 2890

CAUTION:
Be careful not to break O-ring when placing shim(s).
Adjustment shim
Part No. Thickness mm (in)
32190AA000 0.15 (0.0059)
32190AA010 0.30 (0.0118)
NOTE:
When shim is removed, the neutral position will move
closer to reverse; when shim is added, the neutral position
will move closer to 1st gear.
If shims alone cannot adjust the clearance, replace
reverse accent shaft and re-adjust.
Reverse accent shaft
Part No. Mark Remarks
32188AA040 1Neutral position is closer to 1st
gear.
32188AA011 No mark or 2 Standard
32188AA050 3Neutral position is closer to
reverse gear.
B3M0054A
4) Reverse check plate adjustment
NOTE:
After assembling and installing rear case, adjust reverse
check plate.
Shift shifter arm to“5th”and then to reverse to see if
reverse checking mechanism operates properly. Also
check to see if arm returns to Neutral when released from
the reverse position. If arm does not return properly,
replace reverse check plate.
Reverse check plate
Part No.
A: No. AngleθRemarks
32189AA000 0 28°Arm stops closer to 5th gear.
32189AA010 1 31°Arm stops closer to 5th gear.
32189AA020 2 34°Arm stops in the center.
32189AA030 3 37°Arm stops closer to reverse gear.
32189AA040 4 40°Arm stops closer to reverse gear.
32
3-1SERVICE PROCEDURE
3. Rear Case (FWD Model)
Page 789 of 2890
4. Transmission Case
A: DISASSEMBLY
1. SEPARATION OF TRANSMISSION
B3M0329A
B3M0336A
1) Remove clutch release lever1and bearing2. (Refer
to 2-10 clutch.)
G3M0597
2) Remove bearing mounting bolts.
33
3-1SERVICE PROCEDURE
4. Transmission Case
Page 790 of 2890
G3M0598
3) Remove main shaft rear plate4.
B3M0330
4) Separating transmission case
(1) Put vinyl tape around splines of right and left axle
drive shafts to prevent damage to oil seals.
B3M0331
(2) Separate transmission case into right and left
cases by loosening seventeen coupling bolts and nuts.
B3M0101B
5) Remove drive pinion shaft assembly6from left side
transmission case.
NOTE:
Use a hammer handle, etc. to remove if too tight.
6) Remove main shaft assembly
7.
G3M0557
7) Remove differential assembly.
CAUTION:
Be careful not to confuse right and left roller bear-
ing outer races.
Be careful not to damage retainer oil seal.
34
3-1SERVICE PROCEDURE
4. Transmission Case
Page 791 of 2890
2. TRANSMISSION CASE
B3M0060A
A: Front right hand transmission case
B3M0333A
1) Drive out spring pin1with ST, and remove 5th shifter
fork
2.
ST 398791700 STRAIGHT PIN REMOVER
2) Remove plugs
3, springs4and checking balls5.
35
3-1SERVICE PROCEDURE
4. Transmission Case
Page 792 of 2890

B3M0333B
3) Drive out spring pin6, and pull out 3-4 fork rod7and
shifter fork
8.
NOTE:
When removing rod, keep other rods in neutral. Also, when
pulling out straight pin, remove it toward inside of case so
that it may not hit against case.
4) Drive out straight pin
9, and pull out 1-2 fork rod10and
shifter fork
11.
G3M0602
5) Pull out straight pin12, and remove idler gear shaft13,
reverse idler gear
14and washer15.
6) Remove outer snap ring
16, and pull out reverse shifter
rod arm
17from reverse fork rod18. Then take out ball,
spring and interlock plunger from rod.
And then remove rod.
NOTE:
When pulling out reverse shifter rod arm, be careful not to
let ball pop out of arm.
7) Remove reverse shifter lever
19.
G3M0546
8) Remove differential side retainers using ST.
ST 499787000 WRENCH ASSY
G3M0547
9) Remove outer snap ring20and pull out speedometer
driven gear
21. Next, remove vehicle speed sensor 2, oil
seal, speedometer shaft
22and washer.
36
3-1SERVICE PROCEDURE
4. Transmission Case