Page 641 of 3342
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 642 of 3342
5. Drive Pinion Assembly
1. AWD MODEL
B3M0613A
1Drive pinion shaft
2Roller bearing
3Washer
4Driven shaft
5Key
6Woodruff key
7Drive pinion collar
8Needle bearing
9Snap ring (Outer)
10Washer
11Sub gear
121st driven gear
13Baulk ring
141st-2nd synchronizer hub
15Insert key
16Reverse driven gear
17Outer baulk ring
18Synchro cone
19Inner baulk ring
202nd driven gear
212nd driven gear bush
223rd-4th driven gear
23Driven pinion shim
24Roller bearing
255th driven gear
26Lock washer
27Lock nut
28Washer
29Thrust bearing
30Differential bevel gear sleeve
31Washer
32Lock washer
33Lock 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: 265±10 (27±1, 195±7)
10
3-1COMPONENT PARTS
5. Drive Pinion Assembly
Page 643 of 3342
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 644 of 3342
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
Page 645 of 3342
7. Center Differential (AWD Model)
B3M0036A
1Ball bearing
2Snap ring (Inner-110)
3Center differential cover
4Needle bearing
5Adjusting washer
6Viscous coupling
7Pinion shaft
8Differential bevel pinion
9Retainer
10Differential bevel gear
11Washer
12Center differential case
13Snap ring
14Roller bearing
13
3-1COMPONENT PARTS
7. Center Differential (AWD Model)
Page 646 of 3342
8. Front Differential
G3M0515
1Drive pinion shaft
2Hypoid driven gear
3Pinion shaft
4Straight pin
5Washer
6Differential bevel gear
7Differential bevel pinion
8Snap ring (Outer)
9Roller bearing
10Differential case
11Oil seal
12Differential side retainer
13O-ring
14Axle drive shaft
15Retainer lock plate
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 25±5 (2.5±0.5, 18.1±3.6)
T2: 62±5 (6.3±0.5, 45.6±3.6)
14
3-1COMPONENT PARTS
8. Front Differential
Page 647 of 3342
1. General
A: APPLICATION
Large titleModel
AWD FWD
1 General
2Transfer Case and Extension
(AWD Model)
3 Rear Case (FWD Model)
4 Transmission Case
5 Drive Pinion Assembly (AWD Model)
6 Drive Pinion Assembly (FWD Model)
7 Main Shaft Assembly
8 Center Differential (AWD Model)
9 Front Differential
The table above shows the titles of the main sections in
Service Procedures and the applicable vehicle models.
Carry out service operations by referring to the sections
applicable to the vehicle to be serviced.
15
3-1SERVICE PROCEDURE
1. General
Page 648 of 3342

B3M0037A
B: PRECAUTIONS
1) The following job should be followed before disassem-
bly:
(1) Clean oil, grease, dirt and dust from transmission.
(2) Remove drain plug
1to drain oil. After draining,
retighten it as before.
CAUTION:
Replace gasket with a new one.
Tightening torque:
44±3 N⋅m (4.5±0.3 kg-m, 32.5±2.2 ft-lb)
G3M0517
(3) Attach transmission to ST.
ST 499937100 TRANSMISSION STAND SET
2) Rotating parts should be coated with oil prior to assem-
bly.
3) All disassembled parts, if to be reused, should be rein-
stalled in the original positions and directions.
4) Gaskets and lock washers must be replaced with new
ones.
5) Liquid gasket should be used where specified to pre-
vent leakage.
6) Fill transmission gear oil through the oil level gauge
hole up to upper point level gauge.
C: INSPECTION
Disassembled parts should be washed clean first and then
inspected carefully.
1) Bearings
Replace bearings in the following cases:
Bearings whose balls, outer races and inner races are
broken or rusty.
Worn bearings
Bearings that fail to turn smoothly or make abnormal
noise when turned after gear oil lubrication.
B3M0038A
The ball bearing3on the rear side of the drive pinion shaft
2should be checked for smooth rotation before the drive
pinion assembly is disassembled. In this case, because a
preload is working on the bearing, its rotation feels like it is
slightly dragging unlike the other bearings.
Bearings having other defects
16
3-1SERVICE PROCEDURE
1. General