TRANSFER

Page
TROUBLESHOOTING TF-2
ON-VEHICLE REPAIR TF-2
REMOVAL AND INSTALLATION OF TRANSFER TF-3
DISASSEMBLY OF TRANSFER TF-4
COMPONENT PARTS TF-1 1
Rear Output Shaft Assembly TF-1 1
Idler Gear TF-17
Rear Output Shaft Bearing Retainers TF-19
Transfer Front Case TF-22
Diaphragm Cylinder TF-31
Transfer Rear Case TF-35
ASSEMBLY OF TRANSFER TF-37
TI=
TF-2 TRANSFER - Troubleshooting, On-Vehicle Repair

TROUBLESHOOTING
Problem Possible cause Remedy Page

Hard to shift or will not Splines on input shaft dirty or burred Repair as necessary TF-4
shift Transfer faulty Disassemble and inspect
transfer TF-4

Transfer jumps out of Transfer faulty Disassemble and inspect TF-4

gear transfer

ON-VEHICLE REPAIR
ON-VEHICLE REPLACEMENT OF FRONT AND
REAR OIL SEALS
1. DRAIN GEAR OIL FROM TRANSFER

2. REMOVE FRONT AND REAR PROPELLER SHAFTS

(See page PR-2)

3. REMOVE COMPANION FLANGE

(a) Using a hammer and chisel, loosen the staked part of

the nut .

(b) Using SST and two nuts to hold the companion flange,
remove the companion flange lock nut .

SST 09330-00021
(c) Remove the plate washer and companion flange .

4. REPLACE OIL SEAL

(a) Using SST, remove the output shaft oil seal .

SST 09308-10010

• „/'11YV, V,∎ V11 - V GIIR,IG I .Vraa . .

(b) Using SST and hammer, tap in a new oil seal .

SST 09316-60010 (09316-00060)
(c) Apply MP grease to the oil seal lip .

5 . INSTALL COMPANION FLANGE

(a) Install the plate washer, companion flange and a new
lock nut .
(b) Using SST and two nuts to hold the companion flange,
torque the nut .
SST 09330-00021
Torque : 1,300 kg-cm (94 ft-lb, 127 N •m )

l1
(c) Using a punch and hammer, stake the lock nut .

6. INSTALL FRONT AND REAR PROPELLER SHAFTS

(See page PR-2)
Torque : 900 kg-cm (65 ft-lb, 88 N •m )

7. FILL TRANSFER WITH OIL

Oil grade : API GL-4 or GL-5
Viscosity : SAE 90
Capacity : 2 .1 liters (2 .2 US qts, 1 .8 Imp . qts)

REMOVAL AND INSTALLATION OF

TRANSFER
(See page MT-5)

TF-4 TRANSFER - Disassembly of Transfer

DISASSEMBLY OF TRANSFER

COMPONENTS

High and Low Shift Fork

Shaft Assembly
L4 Position Switch
Speedometer Drive Gear

Washer

to Rear Output
Spacer

Shaft Assembly Place Washer

Transfer Front Case L ock Nut
Rear Output Shaft
9-- 1,300 (94, 127)
Front Bearing 0
Retainer
Thrust Washer
Bearing
Spacer •O -Ring
Idler Gear Shaft
Power Take-Off Drive Gear ®k
Transfer Input Gear
Thrust Washer( 4
Lock Plate
650 (47, 64) (17mm bolt)
450 (33, 44) 400 (29, 39) (14mm bolt)

350 (25, 34)

155 (11, 15)

Plate Washer
G asket
Transfer Rear Case •G asket Rear Companion Flange
* •O -Ring
Power Take-Off Cover Speedometer Driven Gear

kg-cm (ft-lb, N •m ) Specified torque

Non-reusable part
Precoated part
DISASSEMBLY OF TRANSFER
(See page TF-4)

1. (DIRECT SHIFT TYPE)

REMOVE TRANSFER FRONT DRIVE SHIFT LEVER
(a) Remove the drive shift lever from transfer .
(b) Remove the dust boot .

(VACUUM SHIFT TYPE)

REMOVE TRANSFER L4 POSITION SWITCH
(a) Disconnect the two connectors .

(b) Remove the transfer L4 position switch .

2. REMOVE SPEEDOMETER DRIVEN GEAR

(a) Remove the bolt and lock plate .

J
f

(b) Remove the speedometer driven gear .

(c) Remove the 0-ring from the speedometer driven gear .
 TF-6 TRANSFER - Disassembly of Transfer

3. REMOVE POWER TAKE-OFF COVER

Remove the six bolts, and remove the power take- off cover
and gasket .

4. INSPECT IDLER GEAR THRUST CLEARANCE

Using a feeler gauge, measure the clearance between the
idler gear and thrust washer .

Standard clearance : 0 .275 - 0 .625 mm

(0 .0110 - 0 .0246 in .)
Maximum clearance : 0 .625 mm (0 .0264 in .)
C

5. REMOVE TRANSFER NO .2 CASE COVER

Remove the six bolts, and remove transfer No .2 case cover
and gasket .

6. REMOVE TRANSMISSION OUTPUT SHAFT LOCK NUT

(a) Using a hammer and chisel, loosen the staked parto

the nut .

(b) Shift the outer lever of the transfer high and lows
lever to H2 or L4 position .
(c) Using SST and two nuts to hold the rear compan
flange, remove the transmission output shaft lock
and plate washer .
SST 09330-00021


TRANSFER - Disassembly of Transfer TF-7

7. REMOVE REAR COMPANION FLANGE

(a) Using a hammer and chisel, loosen the staked part of
the nut .

(b) Using SST and two nuts to hold the rear companion
flange, remove the companion flange lock nut .
SST 09330-00021
(c) Remove the plate washer and companion flange .

8. REMOVE REAR OUTPUT SHAFT REAR BEARING RE-

TAINER
Remove the six bolts, and remove the rear output shaft
bearing retainer and gasket .

9. REMOVE WASHER, SPEEDOMETER DRIVE GEAR AND

SPACER

10 . REMOVE IDLER GEAR SHAFT LOCK PLATE

TRANSFER - Disassembly of Transfer

11 . REMOVE SHIFT PLUGS, SPRINGS AND LOCKING BALLS

[Direct Shift Type]
Remove the shift plugs and, using a magnetic finger, re-
move the springs and locking balls .

[Vacuum Shift Type]

Remove the shift plug, and using a magnetic finger, remove
the spring and locking ball .

12 . REMOVE TRANSFER REAR CASE

(a) Remove the fourteen bolts .
(b) Using a plastic hammer, remove the transfer rear case .
(c) Remove the gasket from the transfer rear case .

(d) Remove the thrust washer from the idler gear shaft,

13 . REMOVE REAR OUTPUT SHAFT ASSEMBLY WITH HIGH

AND LOW SHIFT FORK SHAFT ASSEMBLY


TRANSFER-Disassembly of Transfer TF- 9

14 . REMOVE POWER TAKE-OFF DRIVE GEAR

(a) Using SST, remove the transfer input gear bearing .
SST 09950-20017
(b) Remove the power take-off drive gear .

(c) Remove the spacer .

15 . REMOVE TRANSFER INPUT GEAR

Using SST, remove the transfer input gear .
SST 09950-20017

16 . REMOVE IDLER GEAR AND IDLER GEAR SHAFT

(a) Remove the 0-ring from the idler gear shaft .

1 1

(b) Remove the idler gear with the two bearings and
spacer .
TRANSFER - Disassembly of Transfer

(c) Remove the thrust washer from idler gear shaft .

(d) Remove the idler gear shaft .

(e) Remove the 0-ring from the idler gear shaft .

17 . REMOVE REAR OUTPUT SHAFT FRONT BEARING RE.

TAINER

18 . REMOVE TRANSFER FRONT CASE

(a) Remove the four bolts and using a plastic hammer,
remove the transfer front case .
(b) Remove the gasket and shim .

19 . REMOVE O-RING FROM TRANSMISSION OUTPUT SHA

 TRANSFER - Component Parts (Rear Output Shaft Assembly) TF- 1 1

COMPONENT PARTS
Rear Output Shaft Assembly
COMPONENTS

High and Low

Shift Fork Shaft

High and Low

Shift Fork

Output Shaft
Rear B;%aririb- •

u
70 '\°
- Q
Output Shaft
Front Bearing

S nap Ring
Bearing
I
High and Low
Hub Sleeve
Rear Output Shaft
Bearing
Pilot Bearing
High Gear
Transfer Clutch Hub

Non-reusable part TF0585

DISASSEMBLY OF REAR OUTPUT SHAFT

ASSEMBLY
1. INSPECT THRUST CLEARANCES OF HIGH AND LOW
GEARS
(a) Using a feeler gauge, measure the thrust clearance
between the high gear and bearing .
Standard clearance : 0 .10 - 0 .25 mm
(0 .0039 - 0 .0098 in .)

(b) Using a feeler gauge, measure the thrust clearance

between the low gear and bearing .
Standard clearance : 0 .10 - 0 .25 mm
(0 .0039 - 0 .0098 in .)
TF- 1 2 TRANSFER - Component Parts (Rear Output Shaft Assembly)

2. INSPECT OIL CLEARANCES OF LOW AND HIGH GEARS

(a) Using a dial indicator, measure oil clearance between

the low gear and shaft with the needle roller bearing
installed .
Standard clearance : 0 .019 - 0 .068 mm
(0 .0007 - 0 .0027 in .)
Maximum clearance : 0 .068 mm (0 .0027 in .)

(b) Using a dial indicator, measure oil clearance between

the high gear and shaft with the needle roller bearing
installed .
Standard clearance : 0 .019 - 0 .068 mm
(0 .0007 - 0 .0027 in .)
Maximum clearance : 0 .068 mm (0 .0027 in .)

3. REMOVE LOW GEAR, AND HIGH AND LOW CLUTCH HUB

SLEEVE

(a) Using a press, press out the output shaft rear bear-
ing and low gear .

(b) Remove low gear bearings from the rear output shaft,

(c) Remove the high and low hub sleeve .



TRANSFER - Component Parts (Rear Output Shaft Assembly) TF-13

4. REMOVE TRANSFER CLUTCH HUB AND HIGH GEAR

(a) Using snap ring pliers, remove the snap ring .

(b) Using a press and socket wrench, press out the trans-
fer clutch hub, output shaft front bearing and high
gear .

(c) Remove the high gear bearings from the rear output
shaft .

5 . REMOVE HIGH AND LOW SHIFT FORK SHAFT

(a) Mount the high and low shift fork in a soft jaw vise .
(b) Using a pin punch and hammer, tap out the slotted
spring pin .
(c) Remove the shift fork shaft from the shift fork .

INSPECTION OF REAR OUTPUT SHAFT

ASSEMBLY COMPONENTS
1 . INSPECT REAR OUTPUT SHAFT
(a) Check the rear output shaft for wear or damage .
(b) Using a micrometer, measure the outer diameter of
the rear output shaft journal surface .
Minimum outer diameter :
Part A 40 .009 mm (1 .5752 in .)
B 40 .009 mm (1 .5752 in .)
TF-14 TRANSFER - Component Parts (Rear Output Shaft Assembly)

(c) Place the rear output shaft on V-blocks .

(d) Using a dial indicator, measure the shaft runout .
Maximum runout : 0 .03 mm (0 .0012 in .)

2. INSPECT CLEARANCE OF SHIFT FORK AND HUB SLEE\

Using a feeler gauge, measure the clearance between tl
hub sleeves and shift fork .
Maximum clearance : 1 .0 mm (0 .039 in .)

3. INSPECT HIGH AND LOW HUB SLEEVE

(a) Install the hub sleeve to the rear output shaft .
(b) Check that the hub sleeve moves smoothly .

4. IF NECESSARY, REPLACE REAR OUTPUT SHAFT PILI

BEARING
(a) Using SST, remove the rear output shaft pilot bearir
SST 09319-60020
HINT : The bearing will break .

(b) Using SST and a press, press in a new pilot bearii

SST 09608-20012 (09608-03020)

SST

TF0141


TRANSFER Component Parts (Rear Output Shaft Assembly) TF-15

ASSEMBLY OF REAR OUTPUT SHAFT

ASSEMBLY
1. INSTALL HIGH AND LOW SHIFT FORK SHAFT

(a) Mount the high and low shift fork in a soft jaw vise .

(b) Install the shift fork shaft into the shift fork .

(c) Using a pin punch and hammer, tap in the slotted

spring pin .

2. INSTALL HIGH GEAR AND TRANSFER CLUTCH HUB

(a) Apply MP grease to the high gear bearings .

(b) Install high gear bearings and high gear .

(c) Using SST and a press, press in the output shaft front
bearing .
SST 09316-60010 (09316-00010, 09316-00070)
HINT : Replace both the bearing and the outer race as a
set .

r (d) Using SST and a press, press in the clutch hub .

SST 09316-60010 (09316-00010, 09316-00070)

3. INSTALL SNAP RING

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

Mark Thickness mm (in .)

11 2 .30 - 2 .35 (0 .0906 - 0 .0925)
17 2 .60 - 2 .65 (0 .1024 - 0 .1043)
 ~vullpUI IIL rarLS triear output Shaft Assembly)

(b) Using snap ring pliers, install a new snap ring .

4 . INSTALL LOW GEAR TO REAR OUTPUT SHAFT

(a) Install the high and low hub sleeve .

(b) Apply MP grease to the low gear bearings .

(c) Install low gear bearings and low gear .

(d) Using SST and a press, press in the output shaft rear
bearing .
SST 09316-60010 (09316-00010, 09316-00070)
SST HINT : Replace both the bearing and the outer race asa
set .

w
uu
TF0579
5. INSPECT THRUST CLEARANCES OF HIGH AND LOW
GEARS
(a) Using a feeler gauge, measure the thrust clearance
between the high gear and bearing .
Standard clearance : 0 .10 - 0 .25 mm
(0 .0039 - 0 .0098 in .)
Maximum clearance : 0 .25 mm (0 .0098 in .)
(b) Using a feeler gauge, measure the thrust clearance
between the low gear and bearing .
Standard clearance : 0 .10 - 0 .25 mm
(0 .0039 - 0 .0098 in .)
Maximum clearance : 0 .25 mm (0 .0098 in .)
 TRANSFER - Component Parts (Idler Gear)

Idler Gear
COMPONENTS

Idler Gear Shaft

80 (69 in.-Ib, 7 .8 N •m )

Thrust Washer

[kg-cm(ft-lb, N •m ) Specified torque

Non-reusable part
* Precoated part TF0572

DISASSEMBLY OF IDLER GEAR

1 . REMOVE TWO BEARINGS AND SPACER

2. REMOVE TRANSFER OIL RECEIVER

Remove the three bolts and transfer oil receiver from the
idler gear .


. . .. ~n - %, ouiipuneni rarts (ialer clear)

INSPECTION OF IDLER GEAR COMPONENT

INSPECT THRUST WASHER

Using a micrometer, measure the thrust washer thickness,

Standard thickness : 1 .95 - 2 .05 mm
(0 .077 - 0 .081 in .)
Minimum thickness : 1 .65 mm (0 .065 in .)
If the thickness is less than minimum, replace the thrust
washer .

ASSEMBLY OF IDLER GEAR

Liquid Sealer 1 . INSTALL TRANSFER OIL RECEIVER
(a) Clean the threads of the bolts and case with cleaner,
(b) Apply liquid sealer to the bolt threads .
Sealant : Part No .08833-00070, THREE BOND 1324 or
equivalent

TF0569

(c) Install the transfer oil receiver with the three bolts .
Torque : 80 kg-cm (69 ft-lb, 7 .8 N •m )

2 . INSTALL TWO BEARINGS AND SPACER

(a) Apply MP grease to the two bearings .

(b) Install the two bearings and spacer to the idler gear.


TRANSFER - Component Parts (Rear Output Shaft Bearing Retainers) TF-19

Rear Output Shaft Bearing Retainers

COMPONENTS

90 (78 in.-Ib, 8 .8)

Front Bearing Retainer

kg-cm (ft-Ib, N •m ) Specified torque

4 Non-reusable part TF0584

INSPECTION AND REPAIR OF REAR OUTPUT

SHAFT BEARING RETAINERS
1. IF NECESSARY, REPLACE REAR OUTPUT SHAFT FRONT
BEARING OUTER RACE
(a) Using SST, remove the outer race of the front bear-
ing retainer .
SST 09514-35011

TF0180

(b) Using SST and a press, press a new outer race into
the front bearing retainer .
SST 09316-60010 (09316-00010, 09316-00040)
HINT : Replace both the outer race and the bearing as a
set .


, . . .r L , aI 111001 vuLput :onart bearing Retainers)

2. IF NECESSARY, REPLACE REAR OUTPUT SHAFT RE

BEARING OUTER RACE
(a) Remove the bolt and oil receiver from the rear be
ing retainer .

(b) Using SST, remove the bearing outer race and sh

from the rear bearing retainer .
SST 09514-35011

(c) Install the shim into the rear bearing retainer .

HINT : Reinstall the removed shim .
(d) Using SST, press a new rear outer race into the re
bearing retainer .
SST 09316-60010 (09316-00010, 09316-00030)
HINT : Replace both the outer race and the bearing ass

(e) Install the oil receiver to the rear bearing retainer w

the bolt .
Torque : 90 kg-cm (78 in .-Ib, 8 .8 N •m )

3. IF NECESSARY, REPLACE REAR OUTPUT SHAFT OILS

(a) Using a screwdriver, remove the oil seal .
TRANSFER - Component Parts (Rear Output Shaft Bearing Retainers) TF-21

(b) Using SST and a hammer, tap in a new oil seal .

SST 09316-60010 (09316-00010, 09316-00060)
(c) Apply MP grease to oil seal lip .

4. IF NECESSARY, REPLACE SPEEDOMETER DRIVEN GEAR

OIL SEAL
(a) Using SST, pull out the oil seal .
SST 09921-00010

(b) Using SST, tap a new oil seal into the sleeve .
SST 09201-60011
Oil seal depth : 20 mm (0 .79 in .)


TF-22 TRANSFER - Component Parts (Transfer Front Case)

Transfer Front Case

COMPONENTS

Shift Fork
Diaphragm Cylinder
Snap Ring 185 (13, 18)
*Gasket
Diaphragm Cylinder Body

185(14,18)

1,300 (94, 127)

0
Adjusting Shim

kg-cm (ft-lb, N •m ) Specified torque

• Non-reusable part
Precoated part TF0564

DISASSEMBLY OF TRANSFER FRONT CASE

1. REMOVE 4WD INDICATOR SWITCH

2. [VACUUM SHIFT TYPE]

REMOVE DIAPHRAGM CYLINDER ASSEMBLY
(a) Remove the four bolts, diaphragm cylinder and gasket .

D4363


TRANSFER - Component Parts (Transfer Front Case) TF-23

(b) Remove the shift link lever and straight pin .

E0408 E0409

(c) Remove the four bolts, diaphragm cylinder body and

gasket .

D4284

3. REMOVE FRONT DRIVE HUB SLEEVE

Remove the hub sleeve with front drive shift fork shaft as-
sembly .

64

4. REMOVE FRONT DRIVE SHIFT FORK SHAFT

[Direct Shift Type]
(a) Mount the front drive shift fork shaft in a soft jaw vise .
(b) Using a pin punch and hammer, drive out the slotted
spring pin .
(c) Remove the shift fork from the shift fork shaft .

[Vacuum Shift Type]

(a) Remove the bolt, plate washer, spring and shift fork
:t . from the shift fork shaft .
 TF-24 TRANSFER - Component Parts (Transfer Front Case)

(b) Using snap ring pliers, remove the snap ring .

5. REMOVE FRONT COMPANION FLANGE

(a) Mount the companion flange in a vise .
(b) Using a hammer and chisel, loosen the staked parto
the nut .

(c) Using SST and two nuts to hold the front companio
flange, remove the companion flange lock nut .
SST 09330-00021
(d) Remove the plate washer and companion flange .

6. REMOVE FRONT OUTPUT SHAFT

Using a press, press out the front output shaft .
I

INSPECTION OF TRANSFER FRONT CASE

1. INSPECT CLEARANCE OF SHIFT FORK AND HUB SLEE
Using a feeler gauge, measure the clearance between t
hub sleeve and shift fork .
Maximum clearance : 1 .0 mm (0 .039 in .)


TRANSFER - Component Parts (Transfer Front Case) TF- 2 5

2. INSPECT FRONT DRIVE CLUTCH HUB SLEEVE

(a) Install the clutch hub sleeve to the front output shaft .
(b) Check that the hub sleeve moves smoothly .

3. IF NECESSARY, REPLACE TRANSMISSION REAR OIL

SEAL
(a) Using a screwdriver, remove the oil seal .

(b) Using SST and a hammer, tap in a new oil seal .

SST 09316-60010 (09316-00010, 09316-00030)
(c) Apply MP grease to the oil seal lip .

4. IF NECESSARY, REPLACE FRONT OUTPUT SHAFT OIL

SEAL
(a) Using a screwdriver, remove the oil seal .

(b) Using SST and a hammer, tap in a new oil seal .

SST 09316-60010 (09316-00010, 09316-00060)
(c) Apply MP grease to the oil seal lip .


TF-26 TRANSFER - Component Parts (Transfer Front Case)

5. IF NECESSARY, REPLACE FRONT OUTPUT SH

BEARING
(a) Remove the front output shaft oil seal .
(b) Remove the No .2 oil receiver .

(c) Using a screwdriver, remove the snap ring .

(d) Using SST and a press, press out the bearing .

SST 09608-20012 (09608-00040, 09608-03020)

(e) Using SST and a press, press in a new bearing .

SST 09316-60010 (09316-00010, 09316-00020)

(f) Install the snap ring .

(g) Install the No .2 oil receiver .
(h) Install a new front output shaft oil seal .
TF-28 TRANSFER - Component Parts (Transfer Front Case)

ASSEMBLY OF TRANSFER FRONT CASE

1. INSTALL FRONT OUTPUT SHAFT
Using SST and a press, press in the front output shaft
the transfer front case .
SST 09316-60010 (09316-00010)

2. INSTALL FRONT COMPANION FLANGE

(a) Install the companion flange and plate washer .
(b) Using SST and two nuts to hold the companion flan
install a new companion flange lock nut .
SST 09330-00021
Torque : 1,300 kg-cm (94 ft-lb, 127 N •m )

(c) Mount the companion flange in a vise .

(d) Using a hammer and chisel, stake the compani
flange lock nut .

3. INSTALL FRONT DRIVE SHIFT FORK SHAFT

[Direct Shift Type]
(a) Mount the front drive shift fork in a soft jaw vis
(b) Install the front drive shift fork shaft into shift fo
(c) Using a pin punch and a hammer, drive in the slot
spring pin .

[Vacuum Shift Type]

(a) Using snap ring pliers, install the snap ring .


TRANSFER - Component Parts (Transfer Front Case) TF-29

(b) Install the shift fork, spring and plate washer to the
shift fork shaft with the bolt .
Torque : 185 kg-cm (13 ft-lb, 18 N •m )

TF0224

4. INSTALL FRONT DRIVE HUB SLEEVE

Install the hub sleeve with front drive shift fork shaft as-
sembly .

A0

TF0568

5. (VACCUM SHIFT TYPE)

INSTALL DIAPHRAGM CYLINDER ASSEMBLY

Liquid Sealer (a) Clean the threads of the bolts and case with cleaner .
(b) Apply liquid sealer to the bolts threads .
Sealant : Part No .08833-00070, THREE BOND 1324 or
equivalent

TF0569

(c) Install a new gasket and the diaphragm cylinder body

to the transfer front case with the four bolts .
MW Torque : 185 kg-cm (13 ft-lb, 18 N •m )

/'
D4284

(d) Apply MP grease to the shoe and straight pin .

(e) Install the shift link lever and straight pin .

J
E0409 E0408
-. . - %, uinpuiICnt raris (I ranster Front Case)

(f) Install a new gasket and the diaphragm cylinder to the

diaphragm cylinder body with the four bolts .
Torque : 185 kg-cm (13 ft-lb, 18 N •m )

6. INSTALL 4WD INDICATOR SWITCH



TRANSFER - Component Parts (Diaphragm Cylinder) TF-31

Diaphragm Cylinder
COMPONENTS

Diaphragm Cylinder Cover 375 (27, 37)

I
375 (27, 37) 75 (65 in .-Ib, 7 .4)
Plate

0010 C 15D
1.4~
Diaphragm

185113, 18)

Shoe

Shift Link Lever

Straight Pin

Shoe
N •m ) Specified torque
1 kg-cm (ft-l b,
• Non-reusable part 185 (13,18)
* Precoated part TF0812

DISASSEMBLY OF DIAPHRAGM CYLINDER

1. REMOVE DIAPHRAGM CYLINDER ASSEMBLY
(See page TF-22)

2. REMOVE SHOE FROM SHIFT LINK LEVER

Using a pin punch and hammer, drive out the two shoes
from the shift link lever .
TF-32 TRANSFER - Component Parts (Diaphragm Cylinder)

3. INSPECT DIAPHRAGM CYLINDER ASSEMBLY

(a) With at least 400 mmHg (15 .75 in .Hg, 53 .3 kPa)o
vacuum in the port A or B, check that the shaft moves
(b) Check the stroke between a and b .
Standard stroke : 21 mm (0 .82 in .)
(c) With at least 400 mmHg (15 .75 in .Hg, 53 .3 kPa)o
vacuum in the diaphragm, check that the gauge ne
die is stable .

4. REMOVE SUCTION TUBES

Remove the suction tubes and gaskets from the diaphrag
cylinder and cover .

5. REMOVE DIAPHRAGM CYLINDER COVER AND PUSH R

Remove the six bolts, diaphragm cylinder cover and pu
rod .

6. REMOVE FOLLOWING PARTS FROM DIAPHRAGM PU

ROD
(a) Nut
(b) Two washers
(c) Two plates
(d) Diaphragm
(e) 0-ring
 INSPECTION AND REPAIR OF DIAPHRAGM
CYLINDER
IF NECESSARY, REPLACE OIL SEAL
(a) Using a screwdriver, remove the oil seal .

D2165

(b) Using a socket wrench, tap in a new oil seal .

(c) Apply MP grease to the oil seal lip .

ASSEMBLY OF DIAPHRAGM CYLINDER

1. INSTALL FOLLOWING PARTS TO DIAPHRAGM PUSH ROD
(a) Two washers
(b) Two plates
(c) Diaphragm
(d) 0-ring
(e) Nut

2. TORQUE DIAPHRAGM PUSH ROD NUT

Torque : 375 kg-cm (27 ft-lb, 37 N •m )

3. INSTALL DIAPHRAGM PUSH ROD INTO DIAPHRAGM

CYLINDER
Install the cutout portion of the push rod into the open part
of the diaphragm cylinder .

e
TRANSFER - Component Parts (Diaphragm Cylinder)

4. INSTALL DIAPHRAGM CYLINDER COVER

Install the diaphragm cylinder cover to the diaphragm
cylinder with the six bolts .
Torque : 75 kg-cm (65 in .-lb, 7 .4 N •m )

5. INSTALL SUCTION TUBES

Install the suction tubes with new gaskets .

Torque : 375 kg-cm (27 ft-lb, 37 N •m )

6. INSTALL SHOE TO SHIFT LINK LEVER

Using a press, press in the two shoes to the shift link lever .

7. INSTALL DIAPHRAGM CYLINDER ASSEMBLY

(See page TF-30)


TRANSFER - Component Parts (Transfer Rear Case) TF-35

Transfer Rear Case

COMPONENTS

Plate Washer
High and Low Shift Outer Lever

Plate Washer
Spring Washer

Transfer
Rear Case

High and Low Shift Inner Lever

• Non-reusable part TF0813

DISASSEMBLY OF TRANSFER REAR CASE

REMOVE OUTER AND INNER LEVERS OF TRANSFER HIGH AND
LOW SHIFT
(a) Remove the nut, spring washer, two plate washers
and bolt .
(b) Remove the shift outer lever and washer .
(c) Remove the shift inner lever .

INSPECTION AND REPAIR OF TRANSFER REAR

CASE
IF NECESSARY, REPLACE HIGH AND LOW SHIFT LEVER SHAFT
OIL SEAL
(a) Using a screwdriver, remove the oil seal .
 TF-36 TRANSFER - Component Parts (Transfer Rear Case)

(b) Using SST and a hammer, tap in a new oil seal .

SST 09608-20012 (09608-03020)
(c) Apply MP grease to the oil seal lip .

ASSEMBLY OF TRANSFER REAR CASE

INSTALL OUTER AND INNER LEVERS OF TRANSFER HIGH AND
LOW SHIFT
(a) Install the shift inner lever .
(b) Install the washer and shift outer lever .
(c) Install the bolt, two plate washers, spring washer an
nut .
HINT : Be carefull not to damage the oil seal lip .

TRANSFER - Assembly of Transfer TF-37

Clearance
ASSEMBLY OF TRANSFER
(See page TF-4)
A
Transfer 1. INSTALL ADJUSTING SHIM TO TRANSFER FRONT CASE
Adapter Front Case
(a) Measure the difference of A and B and select a shim
of a thickness for the gap between the transfer adap-
tor and front case to be within the standard clearance .
Standard clearance : 0 .4 - 0 .5 mm
Shim (0 .016 - 0 .020 in .)
TF0258
Adjust shim thickness mm (in .)
2 .28 - 2 .32 (0 .0898 - 0 .0913)
2 .38 - 2 .42 (0 .0937 - 0 .0953)
2 .48 - 2 .52 (0 .0976 - 0 .0992)

(b) Install the adjusting shim to the transfer front case .

D4521

2. INSTALL TRANSFER FRONT CASE

(a) Clean the threads of the bolts and case with cleaning
Liquid Sealer solvent .
(b) Apply liquid sealer to the bolt threads .

Sealant : Part No .08833-00070, THREE BOND 1324 or

equivalent

TF0570

(c) Install a new gasket and transfer front case with the
four bolts .
Torque : 650 kg-cm (47 ft-lb, 64 N •m )

3. INSTALL REAR OUTPUT SHAFT FRONT BEARING RE-

TAINER
Install the rear output shaft front bearing retainer .
TRANSFER - Assembly of Transfer

4. INSTALL IDLER GEAR SHAFT AND IDLER GEAR

(a) Apply gear oil to a new 0-ring and install it to the idler
gear shaft front side groove .
(b) Install the idler gear shaft to the transfer front case .

(c) Install the idler gear thrust washer .

HINT : Be sure that the protruding part of the washer fits
in the case groove .

(d) Install the assembled idler gear, bearings and spacer

to the idler gear shaft .
(e) Apply gear oil to anew 0-ring and install it to the idler
gear shaft rear side groove .

5. INSTALL O-RING TO TRANSMISSION OUTPUT SHAFT

Apply MP grease to a new 0-ring and install it to the trans-
mission output shaft .

6. INSTALL TRANSFER INPUT GEAR

Using SST, install the transfer input gear .
SST 09309-36033


TRANSFER - Assembly of Transfer TF-39

7. INSTALL POWER TAKE-OFF DRIVE GEAR

(a) Install the spacer to the transmission output shaft .

(b) Install the power take-off drive gear to the transmis-

sion output shaft .

(c) Using SST, install the transfer input gear bearing .

SST 09309-36033

8. INSTALL REAR OUTPUT SHAFT ASSEMBLY WITH HIGH

AND LOW SHIFT FORK SHAFT ASSEMBLY

9. INSTALL TRANSFER REAR CASE

(a) Using MP grease, stick the thrust washer to the trans-
fer rear case .
HINT : Be sure that the protruding part of the washer fits
in the case groove .
(b) Place a new gasket on the front case .
TRANSFER - Assembly of Transfer

(c) While aligning the cutout of the shift fork shaft and
shift inner lever, install the transfer rear case .

(d) Install and torque the fourteen bolts .

Torque :
17 mm head bolt 650 kg-cm (47 ft-lb, 64 N •m )
14 mm head bolt 400 kg-cm (29 ft-lb, 39 N •m )

10 . INSTALL LOCKING BALLS, SPRINGS AND SHIFT PLUGS

(a) Clean the threads of the plug and case with cleaning
solvent .
(b) Apply liquid sealer to the plug threads .
Sealant : Part No .08833-00070, THREE BOND 1324
equivalent

[Direct Shift Type]

Install the locking balls and springs, and torque the plug
Torque : 450 kg-cm (33 ft-lb, 44 N •m )

[Vacuum Shift Type]

Install the locking ball and spring, and torque the plu
Torque : 450 kg-cm (33 ft-lb, 44 N •m )


TRANSFER - Assembly of Transfer TF-4 1

11 . INSTALL IDLER GEAR SHAFT LOCK PLATE

Install the lock plate and bolt . Torque the bolt .
Torque : 210 kg-cm (15 ft-lb, 21 N •m )

12 . INSTALL SPACER, SPEEDOMETER DRIVE GEAR AND

WASHER

13 . ADJUST REAR OUTPUT SHAFT BEARINGS PRELOAD

(a) Align the rib with the transfer rear case .
(b) Install the rear bearing retainer .
r

(c) Install and torque the six bolts .

Torque : 350 kg-cm (25 ft-lb, 34 N •m )

(d) Temporarily install a new rear companion flange lock

nut .
(e) Shift the outer lever of the transfer high and low shift
lever to N position .


TF-42 TRANSFER - Assembly of Transfer

(f) Using a torque meter, measure the preload of the rear

output shaft bearings .
Torque : (at starting)
New bearing 15 - 24 .7 kg-cm
(13 .0 - 21 .4 in .-lb,
1 .5-2 .4N •m )
Reused bearing 7 - 12 kg-cm
(6 .1 - 10 .4 in .-Ib,
0 .7 - 1 .2 N •m )
If the preload is not within specification, remove the outer
race of the rear output shaft rear bearing with SST .
SST 09514-35011
Reselect an adjusting shim .

Mark Thickness mm(in .) Mark Thickness mm(in .)

0 0 .15 (0 .0059) 10 1 .00 (0 .0394)
4 0 .40 (0 .0157) 11 1 .10 (0 .0433)
5 0 .50 (0 .0197) 12 1 .20 (0 .0472)
6 0 .60 (0 .0236) 13 1 .30 (0 .0512)
7 0 .70 (0 .0276) 14 1 .40 (0 .0551)
8 0 .80 (0 .0315) 15 1 .50 (0 .0591)
9 0 .90 (0 .0354)

HINT :
• If the preload is more than specification decrease the
thickness of the shim, if less than specification, increase
the thickness of shim .
• The preload will change about 10 .0 kg-cm (8 .7 in .-lb,
f 1 .0 N •m ) with each shim thickness .

(g) Remove the rear companion flange lock nut .

14 . REMOVE REAR BEARING RETAINER



TRANSFER - Assembly of Transfer TF-43

15 . INSTALL REAR BEARING RETAINER

(a) Clean the threads of the bolts and case with cleaner .
(b) Apply liquid sealer to the bolts threads .
Sealant : Part No .08833-00070, THREE BOND 1324 or
equivalent

Liquid Sealer

(c) Place a new gasket on the rear case .

(d) Align the rib with the transfer rear case .
(e) Install the rear bearing retainer .

(f) Install and torque the six bolts .

Torque : 350 kg-cm (25 ft-lb, 34 N •m )

16 . INSTALL REAR COMPANION FLANGE

(a) Install the companion flange and plate washer .
(b) Using SST and two nuts to hold the companion flange,
install a new companion flange lock nut .
SST 09330-00021
Torque : 1,300 kg-cm (94 ft-lb, 127 N •m )

(c) Using a hammer and chisel, stake the companion

flange lock nut .
TF-44 TRANSFER - Assembly of Transfer

17 . INSTALL TRANSMISSION OUTPUT SHAFT LOCK NUT

(a) Shift the outer lever of the transfer high and low shift
lever to H2 or L4 position .
(b) Install the plate washer .
(c) Using SST and two nuts to hold the companion flange,
install a new transmission output shaft lock nut .
SST 09330-00021
Torque : 1,300 kg-cm (94 ft-lb, 127 N .m)

(d) Using a hammer and chisel, stake the transmission

output shaft lock nut .

18 . INSTALL TRANSFER NO .2 CASE COVER

Liquid Sealer (a) Clean the threads of the bolts and case with cleaning
solvent .
(b) Apply liquid sealer to the bolt threads .
Sealant : Part No .08833-00070, THREE BOND 1324 or
equivalent

D4513

(c) Install a new gasket and the transfer No .2 case cover,

with the six bolts . i

(d) Torque the bolts .

Torque : 155 kg-cm (11 ft-lb, 15 N •m )

19 . INSTALL POWER TAKE-OFF COVER

Liquid Sealer (a) Clean the threads of the two bolts and case wit
cleaning solvent .
(b) Apply liquid sealer to the two bolts threads .
Sealant : Part No .08833-00070, THREE BOND 1324
equivalent

TF0570


TRANSFER -Assembly of Transfer TF-45

(c) Install a new gasket and the power take-off cover with
the two sealer coated bolts indicated by arrows and
four bolts as shown .
Torque :
Sealer coated bolts 170 kg-cm (12 ft-lb, 17 N •m )
Other bolts 195 kg-cm (14 ft-lb, 19 N •m )

20 . INSTALL SPEEDOMETER DRIVEN GEAR

(a) Apply gear oil to a new 0-ring .

(b) Install the 0-ring to the speedometer driven gear .

(c) Install the speedometer driven gear with lock plate and
bolt .
Torque : 130 kg-cm (9 ft-lb, 13 N •m )

21 . INSTALL TRANSFER L4 POSITION SWITCH

(a) Install the transfer L4 position switch .

Torque : 250 kg-cm (18 ft-lb, 25 N •m )

(b) Connect the two connectors .

22 . (Direct Shift Type)

INSTALL DUST BOOT
TRANSFER - Assembly of Transfer

23 . (Direct Shift Type)

INSTALL TRANSFER FRONT DRIVE SHIFT LEVER