Page 2377 of 2395

SMT016D
6. Install thrust needle bearing to sun gear.
7. Install sun gear to planetary carrier.
SMT017D
8. Set a support (KV40105500) to bushing replacer puller
(ST30911000) as shown in the figure, and place planetary
carrier on it.
9. Install thrust needle bearing to planetary carrier with its roller
facing front case.
10. Measure ªCº from the end of sun gear to the roller surface of
thrust needle bearing.
SMT018D
11. Measure ªDº from the end of sun gear to the main gear bear-
ing contact surface.
12. Calculate end play ªEº using ªCº and ªDº obtained in steps 10
and 11. Select bearing race so that the end play becomes the
standard value.
Calculation formula:
End play ªEº = ªCº þ ªDº
Standard end play:
0.1 - 0.25 mm (0.0039 - 0.0098 in)
Bearing race:
Refer to SDS, TF-159.
SMT019D
13. Set planetary carrier to press in the status described in step 8.
Then install the selected bearing race to planetary carrier.
SMT020D
14. Install front case to planetary carrier. Set a support ring
(KV40105310) and an adapter B (KV40105230) to main gear
bearing inner race, then press it.
ASSEMBLY
Front Case (Cont'd)
TF-142
Page 2378 of 2395

SMT021D
15. Install washer to sun gear assembly, and select proper snap
ring so that end play ªFº of sun gear is within specifications.
Standard end play ªFº:
0 - 0.15 mm (0 - 0.0059 in)
Snap ring: Refer to SDS, TF-159.
SMT022D
16. Install the selected snap ring.
IDo not reuse snap rings.
17. Apply ATF to the periphery of new transfer cover oil seal, and
attach it at 1.5 mm (0.059 in) from the transfer cover and face.
IDo not reuse oil seal.
SMT023D
18. Apply sealing fluid (Locktite 518´C1335 x 25) to transfer cover
mounting surface of front case as shown in the figure.
CAUTION:
IRemove all foreign materials such as water, oil, and
grease from mating surfaces of front case and transfer
cover.
IPrevent sealing fluid from entering into oil holes of front
case.
SMT024D
19. Align oil hole of front case with notch of transfer cover, and
tighten bolts.
: 49 - 58 N´m (5.0 - 5.9 kg-m, 36 - 43 ft-lb)
IDo not reuse bolts.
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ASSEMBLY
Front Case (Cont'd)
TF-143
Page 2379 of 2395

SMT995C
20. Apply petroleum jelly to radial needle bearing, and install it
inside sun gear.
21. Install shift rod assembly to front case assembly. Refer to ªShift
Rod Assemblyº, TF-144.
22. Install center case assembly to front case assembly. Refer to
ªFinal Assemblyº, TF-153.
23. Install rear case assembly to center case. Refer to ªFinal
Assemblyº, TF-153.
SMT994C
Shift Rod AssemblyNBTF0082S021. Install fork guide, shift fork spring, 2-4 fork, and L-H fork to shift
rod, and secure them with roll pins.
IDo not reuse roll pins.
SMT992C
2. Install 2-4 sleeve and L-H sleeve to each fork.
SMT991C
3. While aligning L-H sleeve with planetary carrier, install shift rod
assembly to front case.
SMT990C
4. Remove all the liquid gasket on check plug and front case, and
install check ball and check spring to front case. Apply gasket
fluid 1215 (Three Bond) to check plug, install it to front case,
and tighten it to specified torque.
IWith plug bolt threaded one pitch into the hole, apply gasket
fluid 1215 (Three Bond) to the thread.
: 19 - 25 N´m (1.9 - 2.5 kg-m, 14 - 18 ft-lb)
5. Remove all the liquid gasket on the switch fitting and inner side
of front case, and with wait detection switch threaded one pitch
into the hole, apply gasket fluid 1215 (Three Bond) to the
thread, install it, and tighten it to specified torque.
ASSEMBLY
Front Case (Cont'd)
TF-144
Page 2380 of 2395

: 15 - 20 N´m (1.5 - 2.0 kg-m, 11 - 14 ft-lb)
IWait detection switch harness connector is black.
6. Install center case assembly to front case assembly. Refer to
ªFinal Assemblyº, TF-153.
7. Install rear case assembly to center case. Refer to ªFinal
Assemblyº, TF-153.
SMT951C
Center Case
ASSEMBLYNBTF0083Oil FilterNBTF0083S011. Apply ATF or petroleum jelly to new O-ring, and install it to oil
filter stud.
IDo not reuse O-rings.
2. Install oil filter stud to center case, and tighten it.
: 25 - 35 N´m (2.6 - 3.6 kg-m, 19 - 26 ft-lb)
SMT939C
3. Apply ATF or petroleum jelly to two new O-rings, and install
them to oil filter.
IDo not reuse O-rings.
4. Install oil filter to center case and tighten bolts.
:7-9N´m(0.7 - 0.9 kg-m, 61 - 78 in-lb)
IDo not knock oil filter with a tool such as a hammer.
SMT935C
Sub-oil PumpNBTF0083S021. Install new oil pump gasket to center case by aligning it with
dowel pin inside the center case.
IDo not reuse gaskets.
SMT936C
2. Install outer gear* and inner gear to sub-oil pump housing, and
measure side clearance. Refer to ªSub-oil Pumpº,
ªINSPECTIONº, TF-138.
3. Set new O-ring to sub-oil pump housing, and install sub-oil
pump cover.
IDo not reuse O-rings.
* Identification mark ªHº is placed on the side of sub-oil pump
cover.
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ASSEMBLY
Front Case (Cont'd)
TF-145
Page 2381 of 2395
SMT955C
4. Align dowel pin hole and mounting bolt hole of sub-oil pump
assembly with center case. Then tighten bolts.
:7-9N´m(0.7 - 0.9 kg-m, 61 - 78 in-lb)
SMT956C
5. Apply ATF or petroleum jelly to new O-ring and install it to
transfer motor.
6. Fit double-flat end of transfer motor shaft into slot of sub-oil
pump assembly. Then tighten bolts.
: 41 - 48 N´m (4.2 - 4.9 kg-m, 30 - 35 ft-lb)
SMT957C
Main Oil PumpNBTF0083S031. Install inner gear and outer gear in the main oil pump housing
with their identification marks facing toward center case
mounting surface side. Then, measure the side clearance.
Refer to ªMain Oil Pumpº, ªCenter Caseº, TF-138.
SMT930C
2. Install main oil pump assembly to center case assembly, and
tighten bolts.
:7-9N´m(0.7 - 0.9 kg-m, 61 - 78 in-lb)
3. Install oil pump shaft to main oil pump, then install rear case
assembly to center case.
Refer to ªFinal Assemblyº, TF-153.
ASSEMBLY
Center Case (Cont'd)
TF-146
Page 2382 of 2395

SMT928C
SMT926C
Control ValveNBTF0083S041. Clean upper body, control valves and springs with cleaning
agent, and apply air blow.
2. Dip control valves in ATF, and apply ATF to the valve-mount-
ing area of upper body.
3. Install each control valve, spring, and plug to upper body, and
fix it with retainer plates.
CAUTION:
ITo insert control valves into upper body, place upper body
on a level surface in order to prevent flaw or damage.
IMake sure each control valve is smoothly inserted.
4. Install reverse balls, relief balls and relief springs, accumula-
tor pistons, valve springs and two filters to upper body.
SMT925C
5. Install lower body and separator plate to upper body.
IDo not reuse separator plates.
SMT962CA
6. With lower body down, tighten two bolts in the position shown
in the figure.
7. Apply ATF or petroleum jelly to new O-ring, and install it to
2-4WD shift solenoid valve, terminal body, line pressure switch
and 4WD solenoid valve. Install them to control valve assem-
bly.
IDo not reuse O-rings.
SMT922CA
8. Apply ATF or petroleum jelly to lip seals, and install them to
center case.
IDo not reuse lip seals.
IThere are 2 kinds of lip seals (lip seal of large inner diam-
eter: 5 pieces, lip seal of small inner diameter: 2 pieces).
Confirm the position before installation.
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ASSEMBLY
Center Case (Cont'd)
TF-147
Page 2383 of 2395

SMT911D
9. Install bolts as shown in the figure, and tighten them to speci-
fied torque.
Bolt symbol a b *c d e f
Length under head
mm (in)38
(1.50)43.5
(1.713)62
(2.44)19
(0.75)52
(2.05)47
(1.85)
Q'ty 1732111
Tightening torque
N´m (kg-m, in-lb)6.9 - 8.8 (0.70 - 0.90, 61.1 - 77.9)
*: Tighten with oil strainer.
SMT920C
10. Install control valve assembly to center case, and tighten bolts.
: 6.9 - 8.8 N´m (0.70 - 0.90 kg-m, 61.1 - 77.9 in-lb)
SMT921C
11. Secure terminal body with snap ring.
SMT919C
12. Apply ATF or petroleum jelly to O-rings, and install them to oil
strainer.
CAUTION:
Do not reuse snap ring.
13. Install oil strainer to control valve assembly.
14. Install mainshaft and clutch drum to center case. Refer to
ªMainshaft and Clutch Drumº, TF-149.
15. Install front case assembly and rear case assembly. Refer to
ªFinal Assemblyº, TF-153.
SMT917C
Clutch PistonNBTF0083S051. Apply ATF to D-ring and lip seal, and install them to clutch pis-
ton.
ASSEMBLY
Center Case (Cont'd)
TF-148
Page 2384 of 2395

SMT969C
2. Set clutch piston to a clutch piston attachment (KV31103400).
SMT970C
3. Set the clutch piston attachment to center case, and install
clutch piston, tap it lightly.
4. Install slide needle bearing race to clutch piston.
SMT915C
5. Remove all the liquid gasket from oil pressure check port and
inside center case. With oil pressure check plug threaded in 1
or 2 pitches, apply gasket fluid 1215 (Three Bond) to the thread
of plug, and tighten.
: 10 - 17 N´m (1.0 - 1.7 kg-m, 87 - 148 in-lb)
6. Install mainshaft and clutch drum. Refer to ªMainshaft and
Clutch Drumº, TF-149.
SMT972C
Mainshaft and Clutch DrumNBTF0083S061. Install drive plates, driven plates and press flange to clutch
hub.
2. Place clutch hub on a surface plate and measure dimension
ªAº between snap ring mounting surface of press flange and
clutch drum sliding face of clutch hub.
CAUTION:
Measure at least 2 points, and take an average.
SMT973C
3. Measure dimension ªBº between the gear end of mainshaft
and the snap ring mounting portion.
4. Calculate end play using dimension ªAº and dimension ªBº
(obtained in steps 2 and 3), and select proper retaining plate
so that the end play is within specifications.
Calculation formula:
End play = B þ A þ Retaining plate thickness
Standard end play:
0.2 - 0.5 mm (0.008 - 0.020 in)
Retaining plate:
Refer to SDS, TF-158.
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ASSEMBLY
Center Case (Cont'd)
TF-149