Page 2974 of 3061

TF-152
< SERVICE INFORMATION >
TRANSFER ASSEMBLY
f. With the lower body down, tighten the two bolts shown.
g. Apply ATF to the new O-rings, and install them to each solenoid
valve, switch and terminal body.
CAUTION:
Do not reuse O-rings.
h. Install the following to the control valve assembly:
• Clutch pressure solenoid valve
• 2-4WD shift solenoid valve
• Clutch pressure switch
• Line pressure switch
• Transfer fluid temperature sensor
10. Apply ATF to the new lip seals, and install them to the center
case.
CAUTION:
• Do not reuse lip seals.
• There are 2 kinds of lip seals (lip seal of large inner diam-
eter: 5 pieces, lip seal of small inner diameter: 2 pieces).
Confirm their position for installation.
11. Install the control valve assembly to the center case, and tighten
to the specified torque. Refer to TF-128, "
Disassembly and
Assembly".
CAUTION:
• Do not reuse any part that has been dropped or damaged.
• Make sure valve is assembled in the proper direction.
• Do not use a magnet because residual magnetism stays
during assembly.
12. Install the connector assembly into the center case, and secure
with a snap ring.
13. Apply ATF to the new O-rings, and install them on the oil
strainer.
CAUTION:
Do not reuse O-rings.
14. Install the oil strainer to the control valve assembly.
WDIA0198E
SDIA2123E
SDIA2121E
SDIA2122E
SDIA2782E
Page 2975 of 3061

TRANSFER ASSEMBLY
TF-153
< SERVICE INFORMATION >
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15. Tighten the bolts to the specified torque. Refer to TF-128, "Dis-
assembly and Assembly".
16. Apply ATF to the new D-rings, and install them to the clutch pis-
ton.
CAUTION:
Do not reuse D-rings.
17. Install the thrust needle bearing race to the clutch piston.
18. Install the clutch piston to the center case as shown.
CAUTION:
Install so the fitting protrusion of clutch piston aligns with
the dent of center case.
19. Remove all the sealant from the oil pressure check port and
inside the center case.
CAUTION:
Remove old sealant adhering to mating surfaces. Also
remove any moisture, oil, or foreign material adhering to
application and mating surfaces.
20. Thread the new oil pressure check plug in 1 or 2 pitches and
apply sealant to the oil pressure check plug threads. Tighten to
the specified torque. Refer to TF-128, "
Disassembly and
Assembly".
•Use Genuine Silicone RTV or equivalent. Refer to GI-45
.
SDIA2119E
SDIA2781E
SDIA2189E
SDIA2190E
SDIA3188E
Page 2979 of 3061
TRANSFER ASSEMBLY
TF-157
< SERVICE INFORMATION >
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35. Apply petroleum jelly to the stem bleeder and install it to the cen-
ter case.
36. Apply ATF to the new seal ring and install it to the main oil pump
cover.
CAUTION:
Do not reuse seal ring.
37. Install the inner gear and outer gear in the main oil pump hous-
ing. Then measure the side clearance. Refer to TF-166, "
Inspec-
tion and Adjustment".
38. Install the main oil pump housing, outer gear and inner gear to
the center case.
39. Install the main oil pump cover to the center case, and tighten to
the specified torque. Refer to TF-128, "
Disassembly and
Assembly".
SDIA2780E
SDIA2783E
SDIA2174E
SDIA2188E
SDIA2130E
Page 2980 of 3061

TF-158
< SERVICE INFORMATION >
TRANSFER ASSEMBLY
40. Remove all the sealant from the switch mating area and inside
the center case.
CAUTION:
Remove old sealant adhering to mating surfaces. Also
remove any moisture, oil, or foreign material adhering to
application and mating surfaces.
41. Thread the ATP switch and neutral-4LO switch in one to two
pitches and apply sealant to the threads of the switches. Tighten
to the specified torque. Refer to TF-128, "
Disassembly and
Assembly".
•Use Genuine Silicone RTV or equivalent. Refer to GI-45
.
NOTE:
• Neutral-4LO switch harness connector is gray.
• ATP switch harness connector is black.
42. Install the front drive shaft rear bearing using Tools.
43. Install the front drive shaft to the front bearing using Tools.
44. Install the drive chain to the front drive shaft and clutch drum.
CAUTION:
Install drive chain by aligning identification marks to the
rear as shown.Tool number A: KV40100621 (J-25273)
B: ST30032000 (J-26010-01)SDIA3435E
SDIA2198E
Tool number A: KV40100621 (J-25273)
B: ST30032000 (J-26010-01)
SDIA2199E
SDIA2200E
Page 2985 of 3061

TRANSFER ASSEMBLY
TF-163
< SERVICE INFORMATION >
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21. Tighten the front case bolts to the specified torque. Refer to
"COMPONENTS".
CAUTION:
Be sure to install harness bracket and air breather hose
clamp.
22. Install the drain plug with a new gasket.
CAUTION:
Do not reuse gasket.
23. Align the matching mark on the front drive shaft with the mark on
the companion flange, then install the companion flange.
24. Install the new companion flange self-lock nut. Tighten to the
specified torque using Tool. Refer to TF-128, "
Disassembly and
Assembly".
CAUTION:
Do not reuse self-lock nut.
25. Remove all the sealant from the check plug, switch mating sur-
face and front case.
CAUTION:
Remove old sealant adhering to mating surfaces. Also
remove any moisture, oil, or foreign material adhering to
application and mating surfaces.
26. Install the check ball and check spring to the front case. Apply
silicone gasket, to the check plug and wait detection switch and
install them to the front case. Tighten to the specified torque.
Refer to TF-128, "
Disassembly and Assembly".
•Use Genuine Silicone RTV or equivalent. Refer to GI-45
.
NOTE:
Wait detection switch harness connector is black.
SDIA2100E
SDIA2779E
Tool number : KV40104000 ( — )
WDIA0219E
WDIA0158E
Page 2986 of 3061

TF-164
< SERVICE INFORMATION >
TRANSFER ASSEMBLY
27. Install the new oil seal in the front case using Tool.
CAUTION:
• Do not reuse oil seal.
• Apply petroleum jelly to seal lip before installing.
28. Install the shift lever to the shift cross.
29. Install the lock pin and lock pin nut. Tighten to the specified
torque. Refer to TF-128, "
Disassembly and Assembly".
Rear Case
1. Apply petroleum jelly to the circumference of the new rear oil
seal. Install the new rear oil seal so that it is flush with the case
tip face using Tool.
CAUTION:
• Do not reuse oil seal.
• Apply petroleum jelly to seal lip before installing.
2. Apply petroleum jelly to the circumference of the new dust cover.
Position the new dust cover using the identification mark as
shown.
CAUTION:
• Do not reuse dust cover.
• Position the identification mark at the position shown.
3. Install the dust cover using Tool.
4. Install the breather tube into the rear case.
5. Remove all the sealant from the rear case to center case mating
surfaces.
CAUTION:
Remove all foreign materials such as water, oil, and grease
from center case and rear case mating surfaces.Tool number : ST22360002 (J-25679-01)
SDIA2182E
Tool number : ST30720000 (J-25405)
SDIA2204E
SDIA3436E
Tool number : KV40105310 ( — )
SDIA2205E
Page 2987 of 3061
TRANSFER ASSEMBLY
TF-165
< SERVICE INFORMATION >
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6. Apply liquid gasket to the entire rear case mating surface of the
center case.
•Use Genuine Anaerobic Liquid Gasket or equivalent.
Refer to GI-45
.
CAUTION:
Do not to allow Liquid Gasket to enter stem bleeder hole.
7. Install the rear case to the center case. Tighten the bolts to the
specified torque. Refer to TF-128, "
Disassembly and Assembly".
SDIA2206E
SDIA2092E
Page 2996 of 3061

WHEEL AND TIRE ASSEMBLY
WT-7
< SERVICE INFORMATION >
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c. If calculated balance weight value exceeds 50 g (1.76 oz), install
two balance weight sheets in line with each other as shown.
CAUTION:
Do not install one balance weight sheet on top of another.
3. Start wheel balancer again.
4. Install drive-in balance weight on inner side of road wheel in the
wheel balancer indication position (angle).
CAUTION:
Do not install more than two balance weights.
5. Start wheel balancer. Make sure that inner and outer residual
imbalance values are 5 g (0.18 oz) each or below.
• If either residual imbalance value exceeds 5 g (0.18 oz),
repeat installation procedures.
Wheel balance (Maximum allowable imbalance):
RotationINFOID:0000000003532691
NOTE:
Follow the maintenance schedule for tire rotation service intervals. Refer to MA-6
.
1. Rotate the tires on each side from front to back as shown. Do
not include the spare tire when rotating the tires.
CAUTION:
When installing wheels, tighten them diagonally by dividing
the work two to three times in order to prevent the wheels
from developing any distortion.
2. Adjust the tire pressure to specification. Refer to WT-28, "
Tire" .
3. After the tire rotation, retighten the wheel nuts after the vehicle
has been driven for 1,000 km (600 miles), and also after every
wheel and tire have been installed such as after repairing a flat tire.
Maximum allowable imbalanceDynamic (At rim flange) 5 g (0.18 oz) (one side)
Static 10 g (0.35 oz)
SMA056D
Wheel nut torque : 133 N·m (14 kg-m, 98 ft-lb)
SMA829C