Page 305 of 4264
SHIFT ON THE FLY SYSTEM 4C2-7
RTW440SH000101
Inner Shaft Bearing
Inspect the state of inner shaft bearing. If any abnormality
such as smoothlessness is found, replace with a new inner
shaft bearing.
Insert a clutch gear and check the state of needle bearing.
If there is an abnormality such as smoothlessness, replace
the needle bearing.
Sleeve
Visual Check
Check and see that there is not wear, damage, or crecking
in the sleeve.
NOTE:
Close inspection of the groove and inner gear are required
because those are important parts.
412RW011
Functional Check
Operate the sleeve with the inner shaft combined with the
clutch gear.
If smoothlessness is felt, replace the sleeve.
NOTE:
Gear oil should be applied to the contact surface of gear.
412RW022
Dimensional Check
Check the width of sleeve center groove.
Sleeve Center Groove (Limit) mm (in)
7.1 (0.28)
Page 306 of 4264

4C2-8 SHIFT ON THE FLY SYSTEM
RTW440SH000201
Clutch Gear
Visual Check
Check and see the there is not wear, damage, crack, or
any other abnormality in the clutch gear.
Functional Check
If there is an abnormality such as soothlessness when
operated in combination with sleeve, replace the clutch
gear.
NOTE:
When inspection, gear oil should be applied to the contact
surface of gear.
RTW440SH000301
Dimensional Check
Make sure of the size illustrated.
Clutch Gear Out Side Diameter (Limit) mm (in)
36.98 (1.46)
RTW440SH000501
RTW440SH000401
Actuator
Visual Check
Check and see that there is no damage, cracking, or other
abnormality.
Functional Check
Make sure of function with voltage (12V) applied to
terminal
3, 4 and set the tester to terminal 1, 2 in
accordance with the table below.
State Port 3Port 4Port 1, 2
Conducting Function
A
C
B
D
If there is an abnormality, replace the actuator as an
assembly.
NOTE:
Be careful not to permit the entry of water or dust into the ports
of the actuator.
Do not open the actuator cover, if the actuator will be reused.
Page 307 of 4264
SHIFT ON THE FLY SYSTEM 4C2-9
RTW440SH000601
RTW440SH000801
Dimension Check
Measure illustration sized A, B, and C
Limit mm (in)
A 64.3 (2.53)
B 6.7 (0.26)
C 6.7 (0.26)
RTW440SH000701
REASSEMBLY
15. Oil seal
Install the new oil seal which has been immersed in
differential gear oil, by using an oil seal installer.
Installer 5-8840-2407-0 (J-41693)
Grip 5-8840-0007-0 (J-8092)
412RS051
14. Needle Bearing
Force a new needle bearing into inner shaft by using a
special tool.
Installer : 5-8840-2408-0 (J-41694)
Grip : 5-8840-0007-0 (J-8092)
Page 308 of 4264
4C2-10 SHIFT ON THE FLY SYSTEM
412RS044
13. Inner Shaft Bearing
Place a new snap ring in inner shaft.
Force a new inner shaft bearing into the inner shaft.
Installer : 5-8840-2197-0 (J-37452)
12. Snap Ring
NOTE;
Be careful not to damage the inner shaft.
11.inner Shaft
Clean the housing contact surface of the front axle
case.
Insert inner shaft assembly into the front axle case.
NOTE:
Be careful not to damage oil seal.
412RW017
10. Snap Ring
Install snap ring in the groove of front axle case.
NOTE:
Be sure to install the snap ring properly.
9. Clutch Gear
Apply differential gear oil to clutch oil.
8. Sleeve
Apply differential gear oil to sleeve.
412RW023
7. Housing
Clean contact surface with the front axle and sctuator
mounting surface.
Apply liquid gasket to the contact surface on the front
axle case and install in the housing.
6. Bolt
Tighten bolts to specified tightening torque.
Housing Bolt Torque N m (kg m/lb ft)
75 (7.6/55)
Page 309 of 4264
SHIFT ON THE FLY SYSTEM 4C2-11
5. Actuator
Clean the actuator contact surface with the housing.
Apply liquid gasket to the contact surface on the
actuator side.
Align shift arm with the groove of sleeve and install the
actuator.
4. Bolt
Tighten bolts to specified torque.
Actuator Bolt Torque N m (kg m/lb ft)
9 (0.95/78)
3. Front Axle Drive Shaft (LH side)
2. Bolt
Install front axle drive shaft and mounting bracket.
Tighten fitting bolts to specified tightening torque.
Bolt Torque N m (kg m/lb ft)
116 (11.8/85)
1. Filler Plug
Pour specified amount of differential gear oil.
Front Differential Oil Capacity liter (US/UK gal)
1.4 (0.37/0.31)
Actuator Housing Oil Capacity liter (US/UK gal)
0.12 (0.03/0.03)
Install filler plug through packing and tighten to
specified torque.
Filler Plug Torque Nm (kgm/lbft)
78 (8.0/58)
Page 310 of 4264
4C2-12 SHIFT ON THE FLY SYSTEM
Torque Specifications N
m (kgf
m / lb ft)
RTW440LF000801
Page 311 of 4264
SHIFT ON THE FLY SYSTEM 4C2-13
SPECIAL SERVICE TOOL
ILLUSTRATION PART NO. PART NAME
5-8840-0007-0
(J-8092)
Grip
5-8840-2407-0
(J-41693)
Installer: Oil seal
5-8840-2408-0
(J-41694)
Installer: Bearing needle
5-8840-0027-0
(J-26941)
Remover: Bearing needle
5-8840-0084-0
(J-2619-01)
Hammer: Sliding
5-8840-2197-0
(J-37452)
Remover: Bearing inner shaft
Page 312 of 4264
4C2-14 SHIFT ON THE FLY SYSTEM
MEMO