Page 3257 of 3371
TF-132
FRONT CASE
Revision: August 20072004 QX56
Measure clearance between shift fork and sleeve. If it is out of
specification, replace it with new one.
Standard value : Less than 0.36 mm (0.0142 in)
SMT010D
Page 3258 of 3371

CENTER CASE
TF-133
C
E
F
G
H
I
J
K
L
MA
B
TF
Revision: August 20072004 QX56
CENTER CASEPFP:33105
InspectionEDS00192
BEARINGS
1. Make sure bearings roll freely and are free from noise, pitting
and cracks.
SUB-OIL PUMP
1. Check inner and outer circumference, tooth face, and side-face
of inner and outer gears for damage or abnormal wear.
2. Measure side clearance between sub oil pump housing edge
and inner gear/outer gear.
3. Make sure side clearance is within specification. If the measure-
ment is out of specification, replace inner and outer gears
together with new ones as a set.
MAIN OIL PUMP
1. Check inner and outer circumference, tooth face, and side-face
of inner and outer gears for damage or abnormal wear.
2. Measure side clearance between main oil pump housing edge
and inner gear/outer gear.
3. Make sure side clearance is within specification. If the measure-
ment is out of specification, replace inner and outer gears with
new ones as a set.
MAINSHAFT
Check surfaces which contact sun gear, clutch drum, clutch hub,
press flange, clutch piston, each bearing, etc. for damage, peel,
partial wear, dents, bending, or other abnormal damage. If any is
found, replace with new one.
SDIA2175E
Specification : 0.015 - 0.035 mm (0.0006 - 0.0014 in)
SDIA2173E
Specification : 0.015 - 0.035 mm (0.0006 - 0.0014 in)
SDIA2174E
SMT944C
Page 3259 of 3371

TF-134
CENTER CASE
Revision: August 20072004 QX56
CONTROL VALVE
Check resistance between terminals of 4WD solenoid valve, 2-
4WD shift solenoid valve and transfer fluid temperature sensor.
Refer to TF-95, "
Component Inspection" .
Check sliding faces of control valves and plugs for abnormality.
If any is found, replace the control valve assembly with new one.
Refer to TF-154, "
Control Valve" .
CAUTION:
Replace control valve body together with clutch return
spring as a set.
Check each control valve spring for damage or distortion, and
also check its free length, outer diameter and wire diameter. If
any damage or fatigue is found, replace control valve body with
new one. Refer to TF-154, "
Control Valve" .
CAUTION:
Replace control valve body together with clutch return spring
as a set.
CLUTCH
Check drive plate facings and driven plate for damage, cracks or
other abnormality. If any abnormalities are found, replace with
new one.
Check the thickness of drive plate facings and driven plate.
Refer to TF-153, "
CLUTCH" .
CAUTION:
Measure facing thickness at 3 points to take an average.
Check all the drive and driven plates.
Check return spring for damage or deformation.
Do not remove spring from the plate
PDIA0183E
SMT947C
SMT948C
SMT949C
Page 3260 of 3371
CENTER CASE
TF-135
C
E
F
G
H
I
J
K
L
MA
B
TF
Revision: August 20072004 QX56
Check stamped mark shown in the figure. Then, check that free
length, (include thickness of plate) are within specifications. If
any abnormality is found, replace with new return spring assem-
bly of the same stamped number.
NOTE:
Specifications, refer to TF-153, "
CLUTCH" .
SDIA2176E
Page 3261 of 3371
TF-136
FRONT CASE
Revision: August 20072004 QX56
FRONT CASEPFP:33107
AssemblyEDS00193
PLANETARY CARRIER, SUN GEAR AND INTERNAL GEAR
1. Install new oil seal until it is seated flush with end face of the
front case, using Tool.
NOTE:
Before installing, apply ATF or petroleum jelly to new oil seal
lip.
Do not reuse oil seal.
2. Install internal gear with its groove facing snap ring into front
case. Then secure it with new snap ring.
NOTE:
Do not reuse snap ring.
3. Set mainshaft front bearing into front case and install, using
Tool.
4. Install new snap ring into front case.
NOTE:
Do not reuse snap ring.
5. Install shift cross to front case.Tool number : KV38100500 ( — )
SDIA2177E
WDIA0100E
Tool number : ST30720000 (J-25405)
SDIA2172E
SDIA2171E
Page 3262 of 3371

FRONT CASE
TF-137
C
E
F
G
H
I
J
K
L
MA
B
TF
Revision: August 20072004 QX56
6. Install oil new seal in front case, using Tool.
NOTE:
Before installing, apply ATF or petroleum jelly to seal lip.
Do not reuse oil seal.
7. Install the shift lever to the shift cross, and lock pin and tighten to
specified torque. Refer to TF-110, "
Transfer Components" .
8. Install the carrier bearing to the sun gear assembly, using Tool.
9. Install new snap ring to sun gear assembly, using suitable tool.
NOTE:
Do not reuse snap ring.
10. Apply ATF to the circumference of the new metal busing prior to
installing it to the sun gear assembly, using Tool.
NOTE:
Do not reuse old metal bushing.
11. Install the needle bearing to the sun gear assembly, using Tool.
NOTE:
Before installing, apply ATF to needle bearing.
Do not reuse old needle bearing.Tool number : ST22360002 (J25679-01)
SDIA2182E
To o l n u m b e r
A : ST30911000 ( — )
B : KV31103300 ( — )
SDIA2179E
SDIA2148E
Dimension A : 7.7 - 8.3 mm (0.303 - 0.327 in)
Tool number : ST35300000 ( — )
SDIA2187E
Dimension B : 62.5 - 63.1 mm (2.461 - 2.484 in)
Tool number : ST33220000 ( — )
SDIA2478E
Page 3263 of 3371
TF-138
FRONT CASE
Revision: August 20072004 QX56
12. Install the sun gear assembly to the planetary carrier assembly.
13. Install new snap ring to planetary carrier assembly.
NOTE:
Do not reuse snap ring.
14. Install front case to planetary carrier assembly, using Tool.
15. Install new snap ring to the sun gear assembly.
NOTE:
Do not reuse snap ring.
16. Apply ATF or petroleum jelly to the circumference of the new oil
seal, and install it to the front case using Tool.
NOTE:
Do not reuse oil seal.
SDIA2180E
SDIA2181E
Tool number : ST33200000 (J-26082)
SDIA2183E
SDIA2144E
Tool number
A : ST30720000 (J-25405)
B : ST33200000 (J-26082)
Dimension : 4.0 - 4.6 mm (0.157 - 0.181 mm)
SDIA2184E
Page 3264 of 3371

FRONT CASE
TF-139
C
E
F
G
H
I
J
K
L
MA
B
TF
Revision: August 20072004 QX56
17. Install shift rod assembly to front case assembly. Refer to TF-139, "SHIFT ROD ASSEMBLY" .
SHIFT ROD ASSEMBLY
1. Install fork guide, shift fork spring, 2-4 fork, and L-H fork to shift
rod, and secure them with new retaining pins.
NOTE:
Do not reuse retaining pins.
2. Install 2-4 sleeve and L-H sleeve to each fork.
3. While aligning L-H sleeve with planetary carrier, install shift rod
assembly to front case.
4. Remove all the liquid gasket on check plug and front case, and
install check ball and check spring to front case. Apply specified
sealant or equivalent, to check plug. Install it to front case, and
tighten to specified torque. Refer to GI-45, "
Recommended
Chemical Products and Sealants" .
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 specified sealant or equivalent, to the
thread. Install it, and tighten to specified torque. Refer to GI-45,
"Recommended Chemical Products and Sealants" .
NOTE:
Wait detection switch harness connector is black.
6. Install center case assembly to front case assembly. Refer to TF-149, "
Final Assembly" .
7. Install rear case assembly to center case. Refer to TF-149, "
Final Assembly" .
SDIA2142E
SMT992C
SDIA2140E
Front case check plug : 22 N·m (2.2 kg-m, 16 ft-lb)
Wait detection switch : 28 N·m (2.9 kg-m, 21 ft-lb)
SDIA2139E