TRANSFER CASE (TOD) 5D2-47
Assembly Procedure
Assembly
Before assembly, lubricate all parts with Automatic Transmission
Fluid or equivalent.
1. If removed, drive the bearing into the front output case bore.
Drive the bearing in staight, making sure it is not cocked in
the bore. Install the internal snap ring that retains the bearing
to the front case.
2. If removed, install the front yoke to flange seal in the front
case bore.
3. If removed, install the yoke to flange seal into the mounting
adapter bore.
4 Sun Gear
5 Thrust Plate
6 Input Shaft
7 Thrust Washer
8 Bearing
9 External Snap Ring
10 Internal Snap Ring
4. If the input shaft needle bearing and bushing were removed,
install a new bearing and bushing as detailed in the following
steps:
Press a new needle bearing, then a new bushing in the
input shaft as follows:
a. Position the input shaft on Axle Bearing/Seal Plate or
equivalent, and Pinion Bearing Cone Replacer as a
spacer.
b. Press a new needle bearing into the end of the input
shaft until it seats in the input shaft.
c. Press in a new bushing.
5. The recessed face of the sun gear and the snap ring groove
on the bearing outer race should be toward the rear of the
transfer case. The stepped face of the thrust washer should
face toward the bearing.
Slide the sun gear, thrust plate and thrust washer into
position on the input shaft. Press the bearing over the input
shaft. Install the external snap ring to the input shaft.
TRANSFER CASE (TOD) 5D2-53
40. Install the rear case flange on the output shaft. Install the
rubber seal, output shaft yoke washer and nut. Tighten
the nut.
Tightening Torque 137 - 196 Nm
41. Install the drainplug and tighten.
42. Fill the transfer case with 1.4 liters of Automatic
Transmission Fluid or equivalent.
Notice
Fluid level should be just below the filler plug hole.
Tightening Torque 19 - 30 Nm
Tightening Torque 19 - 30 Nm 43. Install the fill pulg and tighten.
44. Install the transfer case as outlined in removal and
Installation, transfer case in the section.
Notice
Make sure proper drain and fill plugs are installed if case
is replaced.
BODY WIRING SYSTEM 9A-11
ENGINE ROOM
1 Engine Room Relay Box
1.1 Main Wiring Connector
1.2 Main Wiring Connector
1.3 Main Wiring Connector........................................Gasoline E/G
1.4 Joint
1.5 Compressor, Condenser Fan Relay.....................Diesel E/G
1.6 Condenser Fan Relay 2
1.7 Air Conditioner Relay
1.8 Resistor with Diode..............................................Gasoline E/G
1.9 Front Fog Lamp Relay
1.10 Condenser Fan Relay 1
1.11 Tail Lamp Relay
1.12 Horn Relay
2 Octane Selector...................................................Gasoline E/G with HFM
3 Preheating Unit....................................................Diesel E/G
4 Preheating Timer Unit..........................................Diesel E/G
5 ECS Main Wiring Connector................................ ECS
6 Brake Leveling Fluid Sensor
7 ABD Main Wiring Connector................................ABD 5.0
7-1 ABS Main Wiring Connector................................ABD 5.0
8 ABD main Wiring Connector................................ABD 5.0
9 Engine Temperature Sensor................................Diesel E/G
10 ABS 5.0 ECU.......................................................ABS 5.0
10-1ABD 5.0 Modulator...............................................ABD 5.0
11 Front Washer Motor.............................................Diesel E/G
12 Head Lamp Relay
13 Compressor .........................................................Air Conditioner
14 Wheel Speed Sensor...........................................ABS 5.0 or ABD 5.0
