SECTION 7B1 - MANUAL TRANSMISSION -

4X4 (MUA5C & TRANSFER CASE)

4 X 4 MODEL TRANSMISSION MUA5C

MAIN DATA AND SPECIFICATIONS

GENERAL DESCRIPTION

TORQUE SPECIFICATIONS

STANDARD BOLTS

FLARE NUTS

SPECIAL PARTS FIXING NUTS AND BOLTS

RECOMMENDED LIQUID GASKET

REMOVAL AND INSTALLATION

DISASSEMBLY

EXTERAL COMPONENTS

MAJ OR COMPONENTS

TRANSFER CASE

TRANSMISSION

MINOR COMPONENT

TRANSFER REAR CASE ASSEMBLY

DETENT, SHIFT ARM ASSEMBLY AND INTERLOCK PIN

TRANSFER CASE ASSEMBLY AND MAINSHAFT GEAR

INTERMEDIATE PLATE AND GEAR ASSEMBLY, DETENT, SHIFT ARM ASSEMBLY,

AND INTERLOCK PIN

REVERSE GEAR AND 5TH GEAR

TOP GEAR SHAFT, MAIN GEAR SHAFT, AND COUNTER GEAR

INSPECTION AND REPAIR

REASSEMBLY

MAJ OR COMPONENT

TRANSMISSION

TRANSFER CASE

MINOR COMPONENT

TOP GEAR SHAFT, MAIN SHAFT GEAR AND COUNTER GEAR

REVERSE GEAR AND 5TH GEAR

INTERMEDIATE PLATE AND GEAR ASSEMBLY, DETENT, SHIFT ARM ASSEMBLY

AND INTERLOCK PIN

TRANSFER CASE ASSEMBLY

DETENT, SHIFT ARM ASSEMBLY AND INTERLOCK PIN

TRANSFER REAR CASE ASSEMBLY

EXTERNAL COMPONENTS

4 ×

××

× 4 MODEL TRANSMISSION MUA5C

MAIN DATA AND SPECIFICATIONS

Transmission type Fully synchronized 5-forward and reverse gears.

Transfer case type Constant mesh type Low-High and 2H-4H gears.

Gear ratio :Transmission 1st

2nd

3rd

4th

5th

Rev.

3.767

2.248

1.404

1.000

0.809

3.873

Transfer Case High

Low 1.000

2.050

Oil capacity : Transmission lit (US gal.)

: Transfer Case lit (US gal.) 2.95(0.78)

1.45(0.38)

GENERAL DESCRIPTION

Principle parts of the transmission are the integral clutch housing, the intermediate plate, the rear cover, and the gears.

The gear control box is built-in to the transfer case.

Transfer gear ratio is 1: 2.050.

TORQUE SPECIFICATIONS

STANDARD BOLTS

The torque values given in the following table should be applied where a particular torque is not specified.

N⋅m (kgf⋅m/lb⋅ft)

Strength 4.8/4T 7T 8.8 9.8/9T

Class Refined Non-Refined

Bolt Identifi-

cation

Bolt

Diameter×

××

Pitch (mm) No mark -

M6 × 1. 0 6 (0. 6 / 52 lb.in) 7 (0.7 / 61 lb. i n) 8 (0.8 / 69 lb. i n) -

M8 × 1. 25 13 (1.3 / 113

lb.in) 17 (1.7 / 12) 20 (2.0 / 14) 24 (2.4 / 17)

M10 × 1.25 27 (2.8 / 20) 37 (3.8 / 27) 42 (4.3 / 31) 50 (5.1 / 37)

M12 × 1.25 61 (6.3 / 45) 76 (7.8 / 56) 87 (8.9 / 64) 95 (9.7 / 70)

M14 ×1.5 96 (9.8 / 71) 116 (11.8 / 85) 133 (13.6 / 98) 142 (14.5 / 105)

M16 × 1.5 130 (13.3 / 96) 170 (17.3 / 125) 193 (19.7 / 143) 200 (20.4 / 148)

M18 × 1.5 188 (19.2 / 139) 244 (24.9 / 180) 278 (28.3 / 205) 287 (29.3 / 212)

M20 × 1.5 258 (26.3 / 190) 337 (34.4 / 249) 385 (39.3 / 284) 396 (40.4 / 292)

M22 × 1.5 332 (33.9 / 245) 453 (46.3 / 335) 517 (52.7 / 381) 530 (54.1 / 391)

M24 × 2.0 449 (45.8 / 331) 570 (58.2 / 421) 651 (66.3 / 480) 692 (70.6 / 511)

*M10 × 1.5 26 (2.7 / 20) 36 (3.7 / 27) 41 (4.2 / 30) 48 (4.9 / 35)

*M12 × 1.75 57 (5.8 / 42) 71 (7.2 / 52) 80 (8.2 / 59) 89 (9.1 / 66)

*M14 × 2.0 89 (9.1 / 66) 110 (11.2 / 81) 125 (12.7 / 92) 133 (13.6 / 98)

*M16 × 2.0 124 (12.7 / 92) 162 (16.5 / 119) 185 (18.9 / 137) 191 (19.5 / 141)

Flange Bolt M6 × 1. 0 7 (0. 7 / 61 lb.in) 8 (0.8 / 69 lb. i n) 9 (0.9 / 78 lb. i n) -

M8 × 1. 25 15 (1. 5 / 11) 19 (1.9 / 14) 22 (2.2 / 16) 26 (2. 7 / 20)

M10 × 1.25 31 (3.2 / 23) 41 (4.2 / 30) 47 (4.8 / 35) 56 (5.7 / 41)

M12 × 1.25 69 (7.0 / 51) 85 (8.7 / 63) 97 (9.9 / 72) 106 (10.8 / 78)

M14 × 1.5 104 (10.6 / 77) 126 (12.8 / 93) 144 (14.6 / 106) 154 (15.7 / 114)

M16 × 1.5 145 (14.8 / 127) 188 (19.2 / 139) 214 (21.8 / 158) 221 (22.5 / 163)

M18 × 1.5 - - - -

M20 × 1.5 - - - -

M22 × 1.5 - - - -

M24 × 2.0 - - - -

*M10 × 1.5 30 (3.1 / 22) 40 (4.1 / 30) 46 (4.7 / 34) 54 (5.5 / 40)

*M12 × 1.75 64 (6.5 / 47) 78 (8.0 / 58) 89 (9.1 / 66) 99 (10.1 / 73)

*M14 × 2.0 97 (9.9 / 72) 119 (12.1 / 88) 135 (13.8 / 99.7) 144 (14.7 / 107)

*M16 × 2.0 137 (14.0 / 101) 178 (18.2 / 132) 203 (20.7 / 150) 210 (21.5 / 155)

The asterisk * indicates that the bolts are used for female-threaded parts that are made of soft materials such as

casting, etc.

FLARE NUTS

Pipe diameter mm (in) Torque N⋅

⋅⋅⋅m (kgf⋅

⋅⋅⋅m / lb⋅

⋅⋅⋅ft) Pipe diameter mm (in) Torque N⋅

⋅⋅⋅m (kgf⋅

⋅⋅⋅m / lb⋅

⋅⋅⋅ft)

4.76 (0.187) 16 (1.6 / 12) 10.00 (0.394) 54 (5.5 / 40)

6.35 (0.250) 26 (2.7 / 20) 12.00 (0.472) 88 (9.0 / 65)

8.00 (0.315) 44 (4.5 / 33) 15.00 (0.591) 106 (10.8 / 78)

Standard Hex.

Head Bolt

SPECIAL PARTS FIXI NG NUTS AND BO LTS

N⋅m (kgf⋅m/lb⋅ft)

39 (4/29)

39±10 (4.0±1.0/29±7) 39 (4/29)

127±10

(13±1/94±7)

18.6 (1.9/13.7) 39 (4/29)

39±10

(4.0±1.0/29±7) 39±10

(4.0±1.0/29±7)

137±20

(14±2/101±14.4)

15 (1.5/11)

137±20

(14±2/101±14.4)

RECOMMENDED LIQUID GASKET

Type Brand Name Manufacturer Remarks

ThreeBond 1207B Three Bond

RTV* ThreeBond 1207C Three Bond

Silicon Base ThreeBond 1215 Three Bond For Axle Case and

ThreeBond 1281 Three Bond Transmission Repairs

Water Base ThreeBond 1141E Three Bond For Engine Repairs

ThreeBond 1104 Three Bond

BelcoBond 4 Isuzu

BelcoBond 401 Isuzu

BelcoBond 402 Isuzu

LOCTITE 515 Loctite

LOCTITE 518 Loctite

*RTV: Room Temperature Vulcanizer

Note:

1. It is very important that the liquid gaskets listed above or their exact equivalent is used on the vehicle.

2. Be careful to use the specified amount of liquid gasket.

Follow the manufacturer's instructions at all times.

3. Be absolutely sure to remove all lubricants and moisture from the connecting surfaces before applying the

liquid gasket.

The connecting surfaces must be perfectly dry.

4. LOCTITE 515 and LOCTITE 518 harden upon contact with a metal surface.

Do not apply LOCTITE 515 or LOCTIT E 518 between tw o metal surfaces having a clearance of greater than

0.25 mm (0.01 in). Poor adhesion will result.

For Engine Repairs

Solvent

AllAnerobic

REMOVAL AND INSTALLATION

Read this Section carefully before performing any removal and installation procedure. This Section gives you important

points as well as the order of operation. Be sure that you understand everything in this Section before you begin.

IMPO RTANT OPERATIONS-REMOVAL

Battery Cable

Disconnect the negative (-) cable from the battery terminal.

Engine Hood

Apply setting marks to the engine hood and the engine hood

hinges before removing the engine hood.

Gear Shift Lever and Transfer Change Lever

1. Place the gearshift lever in the neutral position.

2. Place the transfer change lever in the "H" position.

3. Removes the gearshift lever knob and transfer change leve

knob.

4. Remove the center console assembly and front console

assembly.

5. Remove the grommet and dust cover.

6. Remove the gearshift lever cover bolt.

7. Remove the gearshift lever.

8. Remove the transfer change lever retainer bolts.

9. Remove the transfer change lever and O-ring.

Note:

Cover the shift lever and change lever holes to prevent the

entry of foreign material into the transmission.

Lifting the Vehicle

1. Jack up the vehicle.

2. Place chassis stands at the front and the rear of the vehicle.

Transfer Case Protector

Remove the transfer case protector from the transmission

mounting member and the side member.

Transmission and Transfer Case Oil Draining

1. Remove the transmission oil drain plug 1.

2. Remove the transfer case oil drain plug 2,

3. Replace the drain plug(s) after draining the oil.

Exhaus t Pipe

1. Remove the front exhaust pipe.

Rear Propeller Sha ft (Single Shaft Type)

1. Remove the propeller shaft flange yoke at the drive pinion

side 1.

2. Remove the propeller shaft from the transmission main

shaft spline 2.

Rear Propeller Shaft (Dual Shaft Type)

1. Apply setting marks to the 2nd propeller shaft flange yoke.

This will prevent misaligning during the installation procedure.

2. Remove the 2nd propeller shaft flange yoke bolts at the

drive pinion side 1.

3. Remove the center bearing retainer bolts 2.

4. Remove the 1st propeller shaft 3 with the center bearing

and the 2nd propeller shaft.

Pull the 1st propeller shaft toward the rear of the vehicle

until the spline yoke is free of the transmission main shaft.

Front Propeller Shaft

Remove the splined yoke flange bolt at the transfer case side.

Do not allow the splined yoke to fall away from the front

propeller shaft.

IMPORTANT:

Apply setting marks to the splined yoke and the front propeller

shaft before removing the front propeller shaft.

If the splined yoke should fall away from the front propeller

shaft, align the setting marks 3 on the splined yoke 1 and the

propeller shaft 2 to reassemble the two parts.

Harness Connector

Disconnect the 4WD switch connectors, back up light switch

connector and the speedometer sensor connector.

Slave Cylinder

Remove the slave cylinder from the transmission case.

Engine Lifting Hanger

1. Attach the engine-lifting hanger to the front portion of the

engine.

2. Attach the lifting wire to both ends of the engine-lifting

hanger.

ENGINE REAR MOUNTING AND CROSSMEMBER

1. Support the transmission with a transmission jack.

2. Remove No.2 crossmember.

3. Remove the engine rear mounting nuts from No.3

crossmember 3.

4. Remove the engine rear mounting bolts from the

transmission 1.

5. Remove No.3 crossmember and bolts 3 from the side

frame.

6. Remove the engine rear mounting 2.

STARTER M OTOR

Remove the starter motor from the engine rear plate.

TRANSMISSION WI TH TRANSFER

1. Remove the transmission nuts and bolts from the engine

rear plate.

2. Carefully pull the transmission with the transmission jack

toward the rear of the vehicle.

3. Operate the transmission jack to slowly lower the

transmission.

IMPORTANT OPERATIONS - INSTALLATION

Follow the removal procedure in the reverse order to perform

the installation procedure. Pay careful attention to the

important points during the installation procedure.

TRANSMISSION WI TH TRANSFER

1. Apply a thin coat of m olybdenum disulf ide grease to the top

gear shaft spline.

2. Place the transmission on a transmission jack.

3. Carefully move the transmission jack and transmission into

position behind the engine.

4. Slowly raise the transmission jack until the front of the

transmission is aligned with the rear of the engine.

The slope of the engine and the transmission must be the

same.

Starter Motor

1. Install the starter motor to the engine rear plate.

Starter Motor Bolt Torque N⋅m (kgf⋅m/lb⋅ft)

78 ± 16 (8.0 ± 1.6/58 ± 12)

ENGINE REAR MOUNTING AND MOUNTING

MEMBER

1. Install the engine rear mounting to the transmission.

Rear Mounting Bolt Torque N⋅m (kgf⋅m/lb⋅ft

)

41 ± 4.9 (4.2 ± 0.5/30 ± 3.6)

2. Install the mounting member 1 to the mounting rubber 2.

Mounting Rubber Nut Torque N⋅m (kgf⋅m/lb⋅ft)

50 ± 6 (5.1 ± 0.6/37 ± 4.3)

3. Install the mounting member to the side-members.

Mounting Member Bolt Torque N⋅m (kgf⋅m/lb⋅ft)

50 ± 6 (5.1 ±0.6/37 ± 4.3)

SLAVE CYLI NDER

Install the slave cylinder to the transmission case.

Slave Cylinder Bolt Torque

40 ± 10 (4.1 ± 1.0 / 30 ± 7.2)

Harness Connector

Connect the 4WD switch connectors back up light switch

connector and speedometer sensor connector.

FRONT PROPELLER SHAFT

1. Connect the propeller shaft flange yoke to the matching

flange.

2. Tighten the propeller shaft flange yoke bolt to the specified

torque.

Propeller Shaft Flange Yoke Bolt Torque N⋅m (kgf⋅m/lb⋅ft

)

62.7 ±3.9 (6.4 ± 0.4 / 46.3 ± 2.9)

Note:

If the splined yoke and the front propeller shaft have

accidentally separated, align their setting marks and

recouple them.

Refer to "FRONT PROPELLER SHAFT REMOVAL".

REAR PRO PELLER SHAFT (SINGLE SHAFT TYPE)

1. Insert the splined yoke 1 with the propeller shaft into the

transmission main shaft spline 2.

2. Install the propeller shaft flange yoke 3 to the drive pinion

side.

3. Tighten the propeller shaft flange yoke bolt to the specified

torque.

Propeller Shaft Flange Yoke Bolt Torque N⋅m (kgf⋅m/lb⋅ft)

62.7 ± 3.9 (6.4 ± 0.4 / 46.3 ± 2.9)

REAR PRO PELLER SHAFT (DUAL SHAFT TYPE)

1. Place the center bearing 1together with the 1st propelle

shaft 2 and 2nd propeller shaft 7 on the No.4

crossmember 3.

2. Insert the splined yoke 4 into the transmission main shaft

spline 5.

3. Tighten the center bearing retainer bolts 6 to the specified

torque.

Center Bearing Retainer Bolt Torque N⋅m (kgf⋅m/lb⋅ft)

60.8 ± 11.8 (6.2 ± 1.2 / 44.8 ± 8.7)

4. Connect the 2nd propeller shaft 7 and drive pinion side 8.

Be sure to align the setting marks applied at disassembly.

5. Tighten the coupling bolts to the specified torque.

Propeller Shaft Flange Yoke Bolt

Torque N⋅m (kgf⋅m/lb⋅ft)

62.7 ± 3.9 (6.4 ± 0.4 / 46.3 ± 2.9)

Exhaus t Pipe

1. Connect the front exhaust pipe and 2nd-3rd exhaust pipe.

2. Install the exhaust pipe bracket to the transmission case.

TRANSFER CASE PROTECTOR

1. Install the transfer case protector 1 to the mounting

member 2 and the side-members 3.

2. Tighten the transfer case protector bolts to the specified

torque.

Transfer Case Protector Bolt Torque N⋅m (kgf⋅m/lb⋅ft)

36.3 ± 9.8 (3.7 ± 1.0/26.8 ± 7.2)

GEAR SHIFT LEVER AND TRANSFER CHANGE

LEVER

1. Replenish the transm ission case and the tr ansfer c ase with

the specified engine oil.

Transmission and Transfer Case Oil lit (US/UK qt.

)

Transmission Case 2.95 (3.12/2.6)

Transfer Case 1.45 (1.53/1.28)

2. Install the gearshift lever to the gear control box.

Shift Lever Cover Bolt Torque N⋅m (kgf ⋅m/lb⋅ft)

19.6 ± 1.96 (2.0 ± 0.2 / 14.5 ± 1.5)

3. Install the dust cover.

4. Insert the transfer case change lever to the transfer case.

Change Lever Retainer Bolt Torque N⋅m (kgf⋅m/lb⋅ft)

19.6 ± 1.96 (2.0 ± 0.2 / 14.5 ± 1.5)

5. Install the grommet

6. Install the front console assembly and center console

assembly.

7. Install the gearshift lever and the transfer change leve

knobs.

Lowering the Vehicle

1. Place a jack beneath the vehicle.

2. Raise the jack to remove the chassis stands.

3. Lower the vehicle to the ground.

Engine Hood

Align the setting marks (applied at removal) on the engine

hood and the engine hood hinges to install the engine hood.

Battery Cable

Connect the negative (-) cable to the battery terminal.

DISASSEMBLY

EXTERAL COMPONENTS

DISASSEMBLY STEPS

I1. Speedometer sensor and speedometer

driven gear

I2. Transfer flange

I3. Front cover with oil seal

I4. Counter gear snap ring

I5. Bearing snap ring

6. Gear control box assembly

7. Transfer rear case assembly

8. Transmission and transfer case

assembly

IMPORTANT OPERATIONS

1. Speedometer Sensor and Speedometer Driven Gear

Mark the plate 1 and bush 2 alignment for reassembly.

2. Transfer Flange

Use the transfer flange holder to remove the transfer flange.

Transfer Flange Holder: 5-8840-2157-0 (J-37221)

3. Front Cover with Oil Seal

Remove the front cover with oil seal from the transmission

case.

4. Counter Gear Snap Ring

5. Bearing Snap Ring

Use a pair of snap ring pliers to remove the snap ring.

MAJOR COM PONENTS

TRANSFER CASE

DISASSEMBLY STEPS

1. Transfer rear case assembly

2. Shift fork assembly & interlock pin &

detent assembly

3. Transfer case assembly

TRANSMISSION

DISASSEMBLY STEPS

1. Detent assembly

2. Shift fork assembly & interlock pin

3. Rev. and 5th gear assembly

4. Counter gear shaft assembly

5. Top & main gear shaft assembly

MINOR COMPONENT

TRANSFER REAR CASE ASSEMBLY

DISASSEMBLY STEPS

I1. Bearing snap ring

2. Transfer rear case

3. Bearing snap ring

I4. Ball bearing

5. Bearing snap ring

6. Clip

7. Speedometer drive gear

8. Bearing snap ring

I9. Ball bearing

10. Rear output shaft

IMPORTANT OPERATIONS

1. Bearing Snap Ring

Use a pair of snap ring pliers to remove the snap ring.

4. Ball Bearing

Use a bench press and the bearing remover to remove the ball

bearing.

Bearing Remover: 5-8840-0015-0 (J-22912-01)

9. Ball Bearing

Use a bench press and the bearing remover to remove the ball

bearing.

DETENT, SHIFT ARM ASSEMBLY AND INTERLOCK PIN

DISASSEMBLY STEPS

1. Detent ball, spring and plug

I2. Pin and bridge

3. Pin

4. Spring

I5. 2WD-4WD shift rod

6. Shift arm

7. Shift block

8. 4WD indicator switch

I9. Interlock pin

10. Spring

11. Select rod assembly

12. Pin

I13. High-low shift rod

14. Shift arm

15. Shift block

IMPORTANT OPERATIONS

2.Bridge

Use a spring pin remover to remove the spring from the bridge.

5.2WD-4WD Shift Rod

1) Engage the 2nd-4th sleeve with the front output gear.

2) Remove the spring pin from the block.

3) Remove the shift rod.

9.Interlock Pin

Use a magnetic tool to remove the interlock pin from the

transfer case.

13.High-Low Shift Rod

Use a spring pin remover to remove the shift arm spring from

the shift arm and the shift rod.

TRANSFER CASE ASSEM BLY AND MAI NSHAFT GEAR

DISASSEMBLY STEPS

1. Bearing snap ring

I2. Mainshaft end ball bearing

I3. Mainshaft end lock nut

I4. High-low clutch hub and sleeve

I5. Transfer input gear

6. Needle bearing

I7. Bearing collar

8. Ball

I9. Bearing snap ring

10. Front output gear assembly

11. Bearing snap ring

I12. Ball bearing

13. Bearing collar

I14. Anti-lash plate snap ring

15. Spacer

16. Belleville spring

17. Sub gear (Anti-lash plate)

18. Front output gear

19. Needle bearing

20. Clutch hub and sleeve

I21. Ball bearing

22. Front output shaft

23. Bearing snap ring

24. Counter gear assembly

25. Bearing snap ring

I26. Ball bearing

27. Bearing snap ring

I28. Ball bearing

29. Spacer

30. Belleville spring

31. Sub gear (Anti-lash plate)

32. Counter gear

33. Transfer case

IMPORTANT OPERATIONS

2. Mainshaft End Ball Bearing

Use a bearing remover to remove the ball bearing.

Remover : 5-8840-2155-0 (J-37217)

Puller : 5-8840-2027-0

3. Mainshaft End Lock Nut

1) Engage the 3rd-top synchronizer with the 3rd gear.

2) Engage the low-2nd synchronizer with the low gear.

3) Use the lock nut wrench to remove the lock nut.

Lock Nut Wrench: 5-8840-2156-0 (J-37219)

4. High-Low Clutch Hub and Sleeve

5. Transfer Input Gear

Use the universal puller to remove the high-low synchroniser

assembly, the high-low block ring, and the transfer case input

gear.

7. 8. Bearing Collar and Ball

Using screwdriver to remove the bearing collar.

9. Bearing Snap Ring

Use a pair of snap ring pliers to expand the bearing snap ring.

Use a plastic hammer to tap the front output gear assembly

free.

12.Ball Bearing

Use a bench press and the ball bearing remover to remove the

ball bearing.

Bearing Remover: 5-8840-0015-0 (J-22912-01)

14.Anti-lash Plate Snap Ring

Use a pair of pliers to remove the snap ring.

21.Ball Bearing

Use a bench press and the bearing remover to remove the ball

bearing.

Bearing Remover: 5-8840-0015-0 (J-22912-01)

26.Ball Bearing

28.Ball Bearing

Use a bench press and the bearing remover to remove the ball

bearings.

INTERMEDIATE PLATE AND GEAR ASSEMBLY, DETENT,

SHIFT ARM ASSEMBLY, AND INTERLOCK PIN

DISASSEMBLY STEPS

1. Detent spring plate and gasket

2. Detent spring

I3. Detent ball

4. Spring

5. Rev-5th shift rod

6. Rev-5th shift arm and reverse inhibitor

7. 1st-2nd shift rod

I8. 3rd-4th shift rod

I9. 3rd-4th shift arm

I10. 1st-2nd shift arm

I11. Interlock pin

12. Intermediate plate and gear assembly

IMPORTANT OPERATIONS

3.Detent Ball

Use a magnetic tool to remove the detent balls from the

intermediate plate.

Take care not to lose the detent balls.

8.3rd-4th Shift Rod

9.3rd-4th Shift Arm

10.1st-2nd Shift Arm

1) Hold a round bar against the shift arm end.

This will prevent damage to other components.

2) Use a spring pin rem over to rem ove the s hift ar m spring pin

from the shift arm and the shift rod.

Discard the used spring pin.

3) Move the 3rd-4th shift rod forward.

Take care not to lose the interlock pins.

11.Interlock Pin

Carefully remove the reverse shifter rod forward to avoid losing

the interlock pins.

Note:

Remove the shifter rods carefully. Interlock pins are

located between the shifter rod in the intermediate plate.

REVERSE GEAR AND 5TH GEAR

DISASSEMBLY STEPS

I1. Oil seal collar

I2. Bearing

I3. Retainer

4. Thrust plate

5. Thrust washer and lock ball

I6. Reverse idler gear snap ring

7. Reverse idler shaft

8. Idle shaft pin

9. Thrust washer

10. Reverse idler gear

11. Bearing snap ring

I12. Ball bearing

I13. Counter 5th gear

14. Counter reverse gear

15. 5th gear

16. 5th block ring

I17. Needle bearing

I18. Clutch hub nut

I19. Rev-5th synchronizer assembly

I20. Reverse block ring

I21. Reverse gear

22. Needle bearing

I23. Bearing plate and screw

I24. Bearing snap ring

I25. Intermediate plate

IMPORTANT OPERATIONS

1.Oil Seal Collar

2.Bearing

3.Retainer

1) Set the retaining ring remover 1 to the retainer 2 and the

Mainshaft end 3.

2) Remove the r etainer together with the bear ing 4 and the oil

seal collar 5.

The universal puller may be used in place off the retaining

ring remover.

Retainer Remover: 5-8840-2158-0 (J-37222)

Universal Puller: 5-8840-2027-0

6. Reverse Idler Gear Snap Ring

Use a pair of snap ring pliers to remove the snap ring.

12.Ball Bearing

13.Counter 5th Gear

Use the bearing remover to remove the ball bearing.

17.Needle Bearing

Remove the needle bearing (2 piece type).

18.Clutch Hub Nut

1) Engage the 3rd-4th synchronizer with the 3rd gear.

2) Engage the 1st-2nd synchronizer with the 1st gear.

3) Attach the holding fixture together with the holding base to

the mainshaft front bearing and the counter gear front

bearing.

Holding Fixture: 5-8840-2160-0 (J-37224)

Holding Base: 5-8840-0003-0 (J-3289-20)

4) Use the hub nut wrench to remove the hub nut.

Hub Nut Wrench: 5-8840-2156-0 (J-37219)

19.Rev.-5th Synchronizer Assembly

20.Reverse Ring

21.Reverse Gear

Use screw drivers between the reverse gear and bearing plate

to remove the Rev.-5th synchronizer assembly together with

reverse ring and gear.

23.Bearing Plate and Screw

Use the Torx bit to remove the bearing plate screw from the

intermediate plate.

Torx Bit Wrench: 5-8840-0047-0 (J-37225) (T45)

24.Ball Bearing Snap Ring

25.Intermediate Plate

1) Insert the snap ring pliers into the mainshaft bearing snap

ring hole.

2) Use the snap ring pliers 1 to force open the mainshaft

bearing snap ring 2.

Hold the snap ring open with the pliers.

3) Push the intermediate plate toward the rear of the

transmission to remove it.

The ball bearing snap ring will come free.

TOP GEAR SHAFT, MAIN GEAR SHAFT, AND COUNTER GEAR

DISASSEMBLY STEPS

1. Top gear shaft snap ring

2. Top gear shaft

I3. Top gear ball bearing

4. Needle bearing

5. Top block ring

I6. Mainshaft snap ring

I7. 3rd-4th synchronizer assembly

8. 3rd block ring

9. 3rd gear

10. Needle bearing

I11. Needle bearing collar

I12. Mainshaft ball bearing

I13. 1st gear thrust bearing

I14. 1st gear

15. 1st block ring (set)

16. Needle bearing

I17. Clutch hub snap ring

I18. 1st-2nd synchronizer assembly

I19. 2nd block ring (set)

I20. 2nd gear

21. Needle bearing

22. Mainshaft

23. Bearing snap ring

I24. Counter gear front bearing

25. Counter gear center bearing

26. Counter gear

IMPORTANT OPERATIONS

3.Top Gear Ball Bearing

Use a bench press and the bearing remover to remove the ball

bearing.

Bearing Remover: 5-8840-0015-0 (J-22912-01)

6.Mainshaft Snap Ring

Use a pair of snap ring pliers to remove the snap ring.

7.3rd-4th Synchronizer Assembly

1) Use a bench press and the bearing replacer to remove the

synchronizer assembly as a set.

2) Disassemble the synchronizer assembly.

1Springs

2Sleeve

3Clutch Hub

4Inserts

Note:

Mark the hub and sleeve alignment for reassembly.

11.Needle Bearing Collar

12.Mainshaft Ball Bearing

13.1st Gear Thrust Bearing

14.1st Gear

Use a bench press and the bearing remover to remove the ball

bearing.

17.Clutch Hub Snap Ring

Use a pair of snap ring pliers to remove the snap ring.

18.1st-2nd Synchronizer Assembly

19.2nd Block Ring (Set)

20.2nd Gear

1) Use a bench press and the bearing rem over to rem ove the

ball bearing 2nd gear together with synchronizer assembly.

Remover: 5-8840-0015-0 (J-22912-01)

2) Disassemble the synchronizer assembly.

1Springs

2Sleeve

3Clutch Hub

4Inserts

Note:

Mark the hub and sleeve alignment for reassembly.

24.Counter Gear Front Bearing

Use a bench press and the bearing remover to remove the

bearing.

Bearing Remover: 5-8840-0015-0 (J-22912-01)

INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during

inspection.

SHIFT ARM THICKNESS

Use a micrometer to measure the shift arm thickness.

If the measured value is less than the specified limit, the shift

arm must be replaced.

Shift Arm Thickness mm (in)

Standard Limit

1st-2nd

Transfer 4×4/4×2

High/Low

9.60-9.85

(0.378-0.388) 9.0 (0.354)

3rd-4th

Rev.-5th 9.60-9.80

(0.378-0.386)

DETENT AND INTERLOCK SPRINGS FREE LENGTH

Use a vernier caliper to measure the spring's free length.

If the measured value is less than the specified limit, the

springs must be replaced.

Springs Free Length mm (in)

Standard Limit

Transmis s ion 26.8 (1. 06) 26.2 ( 1.03)

Transf er c as e 23.4 (0.92) 22.8 (0. 90)

(I nterlock P in) Transfer c as e 15.9 (0.626) 15.3 (0.602)

(Det ent Ball)

DETENT SPRING TENSION

Use a spring tester to measure the springs tension. If the

measured value is less than the specified standard, the springs

must be replaced.

Springs Tension N⋅m(kgf⋅m/Ib⋅ft)

Compressed

Height Standard

Transmission 20 mm

(0. 787 in) 87.2-97

(8.9-9.9/19.6-

21.8)

Transf er case 18.7 mm

(0. 736 in) 68.6-88.2

(7.0-9.0/15.4-

19.8)

(I nterlock P in) Transfer c as e 115 mm

(0. 453 in) 9.8

(1.0/2.2)

(Det ent Ball)

BLOCK RING AND DOG TEETH CLEARANCE

Use a thickness gauge to measure the clearance between the

block ring and the dog teeth.

If the measured value exceeds the specified limit, the block

ring must be replaced.

Block Ring and Dog Teeth Clearance mm (in)

Standard Limit

1.5 (0.059) 0.8 (0.032)

BLOCK RING AND INSERT CLEARANCE

Use a vernier caliper to measure the clearance between the

block ring and the insert.

If the measured value exceeds the specified limit, the block

ring and the insert must be replaced.

Block Ring and Insert Clearance mm (in)

Standard Limit

3rd-4th 3.46-3.74 (0.136-0.147) 4.0 (0.158)

1st-2nd 4.34-4.66 (0.171-0.183) 4.9 (0.193)

Transfer 2.46-2.74 (0.097-0.108) 3.0 (0.118)

Rev.-5th 3.59-3.91 (0.141-0.154) 4.1 (0.161)

CLUTCH HUB AND INSERT CLEARANCE

Use a thickness gauge to measure the clearance between the

clutch hub and the insert.

If the measured value exceeds the specified limit, the clutch

hub and the insert must be replaced.

Clutch Hub and Insert Clearance mm (in

)

Standard Limit

3rd-4th 0.01-0.19 (0.0004-0.0075) 0.3 (0.012)

1st-2nd

Rev.-5th 0.09-0.31 (0.0035-0.0122) 0.4 (0.016)

MAINSHAFT RUN-OUT

1. Install the mainshaft to a grinding machine.

2. Use a dial indicator to measure the mainshaft central

portion run-out.

If the measured mainshaft run-out exceeds the specified

limit, the mainshaft must be replaced.

Mainshaft Run Out mm (in)

Limit

0.05 (0.0020)

GEAR INSIDE DIAMETER

Use an inside dial indicator to measure the gear inside

diameter.

If the measured value is less than the specified limit, the gear

must be replaced.

Gear Inside Diameter mm (in)

Standard Limit

1st

3rd 45.000-45.013

(1.771-1.772) 45.100 (1.776)

2nd 52.000-52.013

(2.047-2.048) 52.100 (2.051)

Rev.

Transfer 48.000-48.013

(1.889-1.890) 48.100 (1.894)

5th 32.000-32.013

(1.259-1.260) 32.100 (1.264)

REVERSE IDLER GEAR AND IDLER GEAR SHAFT

CLEARANCE

1. Use a micrometer to measure the idler gear shaft diameter.

2. Use an inside dial indicator to m easure the idler gear inside

diameter.

3. Calculate the idler gear and idler gear shaft clearance Idle

gear inside diam eter - idler gear s haft diameter = idler gea

and idler gear shaft clearance.

If the measured value exceeds the specified limit, the idle

gear and/or the idler gear shaft must be replaced.

Idler Gear and Idler Gear Shaft Clearance mm (in)

Standard Limit

0.041-0.074 (0.0016-0.0029) 0.150 (0.0059)

CLUTCH HUB SPLINE PLAY

1. Set a dial indicator to the clutch hub to be measured.

2. Move the clutch hub as far as poss ible to both the right and

the left.

Note the dial indicator reading.

It the meas ur ed value ex ceeds the s pecified lim it, the c lutc h

hub must be replaced.

Clutch Hub Spline Play mm (in)

Standard Limit

1st-2nd

3rd-4th

Transf er 0-0. 1 ( 0- 0.0039) 0. 2 ( 0.0079)

4×2/4×4

High/Low

Rev. - 5th 0-0. 2 ( 0- 0.0079) 0. 3 ( 0.0118)

BALL BEARING PLAY

Use a dial indicator to measure the ball bearing play.

Ball Bearing Play mm (in)

Limit

0.2 (0.0079)

FRONT COVER OIL SEAL

Oil Seal Replacement

Oil Seal Removal

Use a screwdriver to pry the oil seal from the front cover.

OIL SEAL INSTALLATION

1. Use the oil seal installer to install the oil seal to the front

cover.

Oil Seal Installer: 5-8840-0026-0 (J-26540)

2. Apply gear oil to the oil seal lip.

REAR COVER OIL SEAL

Oil Seal Replacement

Oil Seal Removal

Use a screwdriver to pry the oil seal from the rear cover.

OIL SEAL INSTALLATION

1. Use the oil seal installer to install the oil seal to the rea

cover.

Oil Seal Installer: 5-8522-0050 (J-29769)

2. Apply engine oil to the oil seal lip.

TRANSFER CASE MAINSHAFT OIL SEAL

Oil Seal Replacement

Oil Seal Removal

Use a screwdriver to pry the oil seal from the transfer case.

OIL SEAL INSTALLATION

1. Use the oil seal ins taller to install the oil seal to the transf e

case.

Oil Seal Installer: 5-8840-2193-0 (J-37488)

Drive Handle: 5-8840-0007-0 (J-8092)

2. Apply engine oil to the oil seal lip.

TRANSFER CASE FRONT OUTPUT SHAFT OIL SEAL

Oil Seal Replacement

Oil Seal Removal

Use a screwdriver to pry the oil seal from the transfer case.

OIL SEAL INSTALLATION

1. Use the oil seal ins taller to install the oil seal to the tr ansfe

case.

Oil Seal Installer: 5-8840-2161-0 (J-37226)

2. Apply engine oil to the oil seal lip.

REASSEM BLY

MAJOR COM PONENT

TRANSMISSION

REASSEM BLY STEPS

1. Top & main gear shaft assembly

2. Counter gear shaft assembly

3. Rev. and 5th gear assembly

4. Shift arm assembly & interlock pin

5. Detent assembly

TRANSFER CASE

REASSEM BLY STEPS

1. Transfer case assembly

2. Transfer rear case assembly

MINOR COMPONENT

TOP GEAR SHAFT, MAIN SHAFT GEAR AND COUNTER GEAR

REASSEM BLY STEPS

1. Mainshaft

▲2. Needle bearing

▲3. 2nd gear

4. 2nd block ring (set)

▲5. 1st-2nd synchronizer assembly

▲6. Clutch hub snap ring

▲7. Needle bearing

8. 1st block ring (set)

▲9. 1st gear

▲10. 1st gear thrust bearing

▲11. Mainshaft ball bearing

▲12. Needle bearing collar

▲13. Needle bearing

▲14. 3rd gear

15. 3rd block ring

▲16. 3rd-4th synchronizer assembly

▲17. Mainshaft snap ring

18. Needle bearing

19. Top block ring

20. Top gear shaft

▲21. Ball bearing

▲22. Top gear shaft snap ring

23. Counter gear

▲24. Counter gear front bearing

25. Snap ring

26. Counter gear center bearing

IMPORTANT OPERATIONS

2. Needle Bearing

3. 2nd Gear

1) Apply engine oil to the needle bearing and the 2nd gea

thrust surfaces.

2) Install the needle bearing and the 2nd gear to the

mainshaft.

The dog teeth of the 2nd gear must be facing the rear side

of the transmission.

5. 1st-2nd Synchronizer Assembly

1) Turn the shallow clutch hub face 1 toward the side of the

sleeve with small groove 2 on the outer circumference.

Note:

The clutch hub groove

must be aligned with the key

groove of sleeve.

2) Check that the inserts 3 fit snugly into the block ring insert

grooves.

3) Check that the insert springs 4 are fitted to the inserts as

shown in the illustration.

4) Check that the clutch hub 5 and the sleeve 6 slide

smoothly.

5) Install the synchronizer assembly to the mainshaft.

The clutch hub face (with the heavy boss) must be facing

the 2nd gear side.

6. Clutch Hub Snap Ring

1) Select the snap ring, which will provide the minimum

clearance between the 1st/2nd clutch hub and the snap

ring.

There are three snap ring sizes available.

The snap rings are color-coded to indicate their thickness.

Clutch Hub and Snap Ring Clearance mm (in)

Standard

0-0.1 (0.0039)

Snap Ring Availability

Thickness mm (in) Color-Coding

1.80 (0.071) White

1.85 (0.073) Yellow

1.90 (0.075) Blue

2) Use a pair of snap ring pliers to install the snap ring to the

mainshaft.

The snap ring mus t be f ully inserted into the m ains haf t s nap

ring groove.

7.Needle Bearing

9.1st Gear

pply engine oil to the needle bearing and the 1st gea

thrust surfaces.

2) Install the needle bearing and the 1st gear to the mainshaft.

The 1st gear dog teeth must be facing the transmission

front side.

10.1st Gear Thrust Bearing

Install the thrust bearing to the mainshaft.

The thrust bearing side must be facing the transmission front

side.

11.Mainshaft Ball Bearing

12.Needle Bearing collar

1) Apply engine oil to the ball bearing and the mainshaft.

2) Install the ball bearing and collar to the mainshaft.

The ball bearing snap ring groove must be facing the

transmission rear side.

3) Use a bench press to slowly force the collar into place.

Installer: 5-8840-2195-0 (J-6133-01)

13.Needle Bearing

14.3rd Gear

1) Apply engine oil to the needle bearing and the 3rd gea

thrust surfaces.

2) Install the needle bearing and the 3rd gear to the mainshaft.

The dog teeth of the 3rd gear m ust be facing the front side

of the transmission.

16.3rd-4th Synchronizer Assembly

1) Turn the clutch hub face 1 with the heavy boss Atoward

the side of the sleeve with small groove 2on the oute

circumference.

2) Check that the inserts 3 fit snugly into the block ring insert

grooves.

3) Check that the insert springs 4 are fitted to the inserts as

shown in the illustration.

4) Check that the clutch hub 5 and the sleeve 6 slide

smoothly.

5) Install the synchronizer assembly to the mainshaft.

The clutch hub face (with the heavy boss) must be facing

the 3rd gear side.

17.Mainshaft Snap Ring

1) Select the snap ring, which will provide the minimum

clearance between the 3rd-4th clutch hub and the snap

ring.

There are three snap ring sizes available.

The snap rings are color-coded to indicate their thickness.

Clutch Hub and Snap Ring Clearance mm (in)

Standard

0-0.1 (0.0039)

Snap Ring Availability mm (in)

Thickness Color-Coding

1.80 (0.071) White

1.85 (0.073) Yellow

1.90 (0.075) Blue

2) Use a pair of snap ring pliers to install the snap ring to the

mainshaft.

3) The snap ring mus t be f ully inserted into the m ains haf t s nap

ring groove.

21.Ball Bearing

22.Top Gear Shaft Snap Ring

1) Use a bench press to install the top gear shaft ball bearing

to the mainshaft.

The snap ring groove m ust be fac ing the transmiss ion front

side.

2) Use a pair of snap ring pliers to install the snap ring to the

bearing.

24.Counter Gear Front Bearing

Use a bench press to install the counter gear front bearing to

the mainshaft.

The snap ring groove must be facing the transmission front

side.

Bearing installer: 5-8840-2194-0 (J-35283)

1) Apply engine oil to the bearing and install the inner race 1

and outer race with roller 2 in the proper direction to the

mainshaft.

2) Then install the inner r ace 3with taper side turned to oute

race 2.

Note:

The inner race 3 should be installed with stamp on die

face side turned to the front side of transmission.

REVERSE GEAR AND 5TH GEAR

REASSEM BLY STEPS

▲1. Intermediate plate

2. Bearing snap ring

▲3. Bearing plate and screw

4. Needle bearing

5. Mainshaft reverse gear

6. Reverse block ring

▲7. Rev.-5th synchronizer assembly

▲8. Clutch hub nut

9. Needle bearing

10. 5th block ring

11. 5th gear

▲12. Counter reverse gear

13. Counter 5th gear

14. Ball bearing

15. Reverse idler gear

16. Thrust washer

17. Idler shaft pin

18. Reverse idler shaft

▲19. Bearing snap ring

▲20. Reverse gear snap ring

▲21. Thrust washer and lock ball

22. Thrust plate

23. Retainer

▲24. Roller bearing

25. Oil seal collar

IMPORTANT OPERATIONS

1. Intermediate Plate

1) Mesh the counter gear with the mainshaft assembly.

2) Install the holding fixture to the mainshaft and the counte

gear.

Holding Fixture: 5-8840-2160-0 (J-37224)

Holding base: 5-8840-0003-0 (J-3289-20)

3) Place the holding fixture (with the mainshaft and the counte

shaft) in a vise.

4) Install the intermediate plate.

3. Bearing Plate and Screw

1) Apply recom mended thr ead locking agents or its equivalent

to each of the plate screw threads.

2) Use the wrench to tighten the screws to the specified

torque.

Torx Bit Wrench: 5-8840-0047-0 (J-37225) (T45)

Plate Screw Torque N⋅m (kgf⋅m/lb⋅ft)

15 (1.5/11)

7. Rev.-5th Synchronizer Assembly

1) Turn the clutch hub face 1 toward the side of the sleeve

with small groove 2 on the outer circumference.

2) Check that the inserts 3 fit snugly into the block ring insert

grooves.

3) Check that the insert springs 4 are fitted to the inserts as

shown in the illustration.

4) Check that the clutch hub 5 and the sleeve 6 slide

smoothly.

5) Install the synchronizer assembly to the mainshaft.

The clutch hub face (with the heavy boss) must be facing

the reverse gear side.

8. Clutch Hub Nut

1) Mesh the 1st-2nd synchronizer with both the 1st and 3rd

gears (double engagement).

This will prevent the mainshaft from turning.

2) Install the mainshaft lock nut.

3) Use the lock nut wrench to tighten the lock nut to the

specified torque.

Wrench: 5-8840-2156-0 (J-37219)

Hub Nut Torque N⋅m (kgf⋅m/lb⋅ft)

137 ± 20 (14 ± 2 / 101 ± 14.4)

4) Use a punch to stake the lock nut.

12.Counter Reverse Gear

1) Apply engine oil to the counter reverse gear and the reverse

gear.

2) Install the counter reverse gear to the counter gear.

The reverse gear projection must be facing the side of the

intermediate plate.

19.Bearing Snap Ring

1) Select the snap ring, which will provide the minimum

clearance between the ball bearing and the snap ring.

There are six snap ring sizes available.

The snap rings are color-coded to indicate their thickness.

Ball Bearing and Snap Ring Clearance mm (in)

Standard 0-0.15 (0-0.0059)

Snap Ring Availability mm (in)

Thickness mm (in) Color-Coding

1.1 (0.043) White

1.2 (0.047) Yellow

1.3 (0.051) Blue

1.4 (0.055) Pink

1.5 (0.059) Green

1.6 (0.063) Brown

2) Use a pair of snap ring pliers to install the snap ring to the

counter 5th gear.

The snap ring must be fully inserted into the counter 5th

gear snap ring groove.

20.Reverse Gear Snap Ring

1) Select the snap ring, which will provide the minimum

clearance between the intermediate plate and the snap ring.

There are three snap ring sizes available.

The snap rings are color-coded to indicate their thickness.

Intermediate Plate and Snap Ring Clearance mm (in)

Standard 0-0.15 (0-0.0059)

Snap Ring Availability mm (in

)

Thickness mm (in) Color-Coding

1.2 (0.047) White

1.3 (0.051) Yellow

1.4 (0.055) Blue

2) Use a pair of snap ring pliers to install the snap ring to the

reverse idler shaft.

The snap ring must be fully inserted into the reverse idle

shaft snap ring groove.

21.Thrust Washer and Lock Ball

1) Use a thickness gauge to measure the clearance between

the 5th gear and the thrust washer.

5th Gear and Thrust Washer Clearance mm (in)

Standard

0.10-0.25 (0.0039-0.0098)

If required, replace the existing thrust washer with a new thrust

washer to bring the clearance to specification.

There are four thrust washer sizes available.

The snap rings are color-coded to indicate their thickness.

Thrust Washer Availability mm (in)

Thickness Color-Coding

7.9 (0.311) White

8.0 (0.315) Yellow

8.1 (0.319) Green

8.2 (0.323) Blue

2) Apply grease to the thrust washer and the lock ball.

3) Install the thrust washer and the lock ball to the mainshaft.

24.Roller Bearing

Apply engine oil to the bearing inner and outer circumference.

Use the installer to install the roller bearing to the mainshaft.

Installer: 5-8840-2159-0 (J-37223)

Note:

Be sure the bearing is installed in the direction it was

removed from.

INTERMEDIATE PLATE AND GEAR ASSEMBLY, DETENT,

SHIFT ARM ASSEMBLY AND INTERLOCK PIN

REASSEM BLY STEPS

1. Intermediate plate and gear assembly

▲2. 1st-2nd shift arm

▲3. 3rd-4th shift arm

▲4. 3rd-4th shift rod

▲5. Interlock pin

6. 1st-2nd shift rod

7. Rev.-5th shift arm and inhibiter

8. Rev.-5th shift rod

9. Spring

10. Detent ball

11. Detent spring

▲12. Detent spring plate and gasket

IMPORTANT OPERATIONS

2. 1st-2nd Shift Arm

3. 3rd-4th Shift Arm

Hold a round bar 1 against the shift rod end lower face 2 to

protect it against damage.

Install the new spring pin.

Never reinstall the used spring pin.

4. 3rd-4th Shift Rod

5. Interlock pin

1) Install the interlock pin to the shift rod.

2) Install the shift rod together with the interlock pin to the

intermediate plate.

Do not allow the interlock pin to fall from the shift rod.

12.Detent spring Plate and Gasket

1) Install the new-detent plate and new gasket onto the

transmission case into the correct direction.

2) Tighten the detent spring plate bolts to specified torque.

Detent Spring Plate Bolt Torque N⋅m (kgf⋅m/lb⋅ft)

20 ± 4 (2.0 ± 0.4 / 14 ± 3)

TRANSFER CASE ASSEM BLY

REASSEM BLY STEPS

▲1. Transfer case

▲2. Counter gear

▲3. Sub gear (Anti-lash plate)

4. Belleville spring

5. Spacer

6. Ball bearing

▲7. Snap ring

8. Ball bearing

9. Snap ring

10. Counter gear assembly

11. Bearing snap ring

12. Front output shaft

13. Ball bearing

14. Clutch hub and sleeve

15. Needle bearing

▲16. Front output gear

▲17. Sub gear (Anti-lash plate)

▲18. Belleville spring

▲19. Spacer

▲20. Anti-lash plate snap ring

▲21. Bearing collar

22. Ball bearing

▲23. Snap ring

24. Front output gear assembly

25. Bearing snap ring

26. Ball

27. Bearing collar

28. Needle bearing

29. Transfer input gear

▲30. High-low clutch hub and sleeve

▲31. Mainshaft end lock nut

▲32. Ball bearing

33. Snap ring

IMPORTANT OPERATIONS

1. Transfer Case

1) Cover the shaft spline with adhesive tape 1.

This will prevent damage to the oil seal lip 2.

2) Apply recommend liquid gasket or its equivalent to the

transfer case fitting surfaces.

3) Tighten the transfer cas e bolts to the spec if ied tor que a little

at a time.

Transfer Case Bolt Torque N⋅m (kgf⋅m/lb⋅ft

)

39.2 ± 7.8 (3.8 ± 0.8 / 27.5 ± 5.8)

2. Counter Ge ar

3. Sub Gear (Anti-lash Plate)

Apply chassis grease to the sub-gear and the counter gear

thrust surfaces.

7. Snap Ring

1) Select a snap ring that will allow the minimum axial play.

2) Use a pair of snap ring pliers to install the snap ring to the

counter gear.

Bearing and Snap Ring Clearance mm (in)

Standard

0-0.1 (0-0.0039)

Snap Ring Availability mm (in)

Thickness Color-Coding

1.50 (0.059) White

1.55 (0.061) Yellow

1.60 (0.063) Blue

16.Front Output Gear

17.Sub Gear (Anti-lash Plate)

18.Belleville Spring

19.Spacer

Apply engine oil to the thrust surfaces of the sub-gear, the

belleville spring, and the spacer.

20.Anti-lash Plate Snap Ring

21.Bearing Collar

Use a bench press to install the needle bearing and collar

together with the front output gear.

23.Snap Ring

1) Select a snap ring that will allow the minimum axial play.

2) Use a pair of snap ring pliers to install the snap ring to the

output shaft.

Bearing and Snap Ring Clearance mm (in)

Standard

0-0.1 (0-0.0039)

Snap Ring Availability mm (in)

Snap Ring Thickness Color Coding

1.55 (0.061) White

1.60 (0.063) Yellow

1.65 (0.065) Blue

1.70 (0.067) Pink

1.75 (0.069) Green

1.80 (0.071) Brow n

1.85 (0.073) Red

1.90 (0.075) Orange

30.High-Low Clutch Hub and Sleeve

The clutch hub face with the heavy bass must be facing the

transfer input gear side.

SUB GEAR (ANTI-LASH PLATE) PRELO AD

1) Hook a length of piano wire over one of the sub-gear teeth.

2) Attach the other end of the piano wire to a spring balancer.

3) Measure the sub-gear preload.

Sub-Gear Preload N (kg/lb)

Standard

59-98 (6-10 / 13-22)

32.Mainshaft End Lock Nut

1) Use the lock nut wrench to tighten the mainshaft end lock

nut to the specified torque.

Lock Nut Wrench: 5-8840-2156-0 (J-37219)

Mainshaft End Lock Nut Torque N⋅m (kgf⋅m/Ib⋅ft)

137 ± 20 (14 ± 2/101 ± 14.4)

2) Stake the lock nut.

33.Ball Bearing

Use the ball bearing installer to install the ball bearing.

Installer: 5-8840-2159-0 (J-37223)

DETENT, SHIFT ARM ASSEMBLY AND INTERLOCK PIN

REASSEM BLY STEPS

1. Shift block

2. Shift arm

▲3. High-low shift rod

▲4. Spring pin

5. Select rod assembly

6. Shift block

7. Shift arm

8. Spring

▲9. Interlock pin

▲10. 2WD-4WD shift rod

▲11. 4WD indicator switch

▲12. Spring pin

13. Spring

14. Pin and bridge

▲15. Detent ball, spring and plug

IMPORTANT OPERATIONS

3.High-Low Shift Rod

4.Spring Pin

1) Engage the High-Low sleeve with 4H side.

2) Install the spring pin to the shift block.

9.Interlock Pin

10.2WD-4WD Shift Rod

1) Engage the High-Low synchronizers with 4H side and install

the interlock pin 1 in proper direction.

2) Install the shift rod: 2WD-4WD 2 with the interlock pin

pushed it in.

12.Spring Pin

1) Engage the 2WD-4WD sleeve with the 4WD side and install

the spring pin.

11.4WD Indicator Switch

Tighten the switch to the specified torque.

Switch Torque N⋅m (kgf⋅m/lb⋅ft)

39.2 (4/29.0)

15.Detent Ball, Spring and Plug

Tighten the plugs to the specified torque.

Plug Torque N⋅m (kgf⋅m/lb⋅ft)

18.6 ± 3.9 (1.9 ± 0.4 / 13.7 ± 2.9)

TRANSFER REAR CASE ASSEMBLY

REASSEM BLY STEPS

1. Rear output shaft

▲2. Ball bearing

3. Bearing snap ring

▲4. Clip

5. Speedometer drive gear

6. Bearing snap ring

▲7. Ball bearing

8. Bearing snap ring

9. Rear case

10. Bearing snap ring

IMPORTANT OPERATIONS

2. Ball Bearing

Use the ball bearing installer and the adapter to install the ball

bearing.

Ball Bearing Installer: 5-8840-2159-0 (J-37223)

Adapter: 5-8840-2192-1 (J-37486-A)

4. Clip

Install the clip to the drive gear groove.

7. Ball Bearing

Use the ball bearing installer to install the ball bearing.

Ball Bearing Installer: 5-8840-2159-0 (J-37223)

EXTERNAL COM PONENTS

REASSEM BLY STEPS

1. Transmission and transfer assembly

▲2. Transfer rear case assembly

3. Gear control box assembly

▲4. Counter gear snap ring

▲5. Bearing snap ring

▲6. Front cover with oil seal

▲7. Transfer flange

▲8. Speedometer driven gear and

speedometer sensor

IMPORTANT OPERATIONS

2. Transfer Rear Case Assembly

1) Apply recommended liquid gasket or its equivalent to the

transfer rear case fitting faces.

pply the following steps before fitting the transfer rea

case.

1Shift the High-Low synchronizer to the 4H side.

2Turn the select rod counterclockwise so that the select

block projection A may enter into the 2WD-4WD shift

block.

When the rear case is fitted under this condition 2, the

direction of the c ut-away portion of select r od head Baligns

with that of the rear case hole stopper C.

3) Tighten the rear transfer rear case bolts to the specified

torque.

Transfer Case Bolt Torque N⋅m (kgf⋅m/lb⋅ft)

37.2 ± 7.8 (3.8 ± 0.8 / 27.5 ± 5.8)

4. Counter Gear Snap Ring

5. Bearing Snap Ring

Use a pair of snap ring pliers to install the snap ring to the

mainshaft.

The snap ring must be fully inserted into the ball bearing snap

ring groove.

6. Front Cover with Oil Seal

1) Apply recommended liquid gasket or its equivalent to the

through bolt threads.

2) Install the new gask et and the f r ont co ver with oil seal to the

transmission ca se.

Take care not to damage the oil seal.

3) Tighten the front cover bolts to the specified torque.

Front Cover Bolt Torque N⋅m (kgf⋅m/lb⋅ft)

18.6 ± 3.9 (1.9 ±0.4 / 13.7 ± 2.9)

7. Transfer Flange

1) Use the flange holder to install the flange to the rea

transfer case.

Flange Holder: 5-8840-2157-0 (J-37221)

2) Tighten the transfer flange bolts to the specified torque.

Transfer Flange Bolt Torque N⋅m (kgf⋅m/lb⋅ft

)

137 ± 20 (14 ± 2 / 101 ± 14.4)

8. Speedometer Driven Gear and Speedometer Sensor

1) Install the O-ring to the speedometer driven gear bushing.

2) Install the driven gear to the speedometer driven gea

bushing.

3) Align the matching marks on plate 1 and bush 2 then

tighten the bolt.

Bolt Torque N⋅m (kgf⋅m/lb⋅ft)

14.7 (1.5/10.8)

4) Install the speedometer sensor. N⋅m (kgf⋅m/lb⋅ft)

27 (2.8/20)