Transfer Assembly: Reassembly

Using a feeler gauge, measure the clearance between the shift fork No. 2 and clutch sleeve.

1. Standard clearance: 0.10 - 0.40 mm (0.0039 - 0,0157 In.) 
2. Maximum clearance: 0.40 mm (0.0157 in.) 

Fig 1: Measuring Clearance Between Shift Fork & Clutch Sleeve Using Feeler Gauge

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Using SST and a press, install the bearing race.

1. SST 09316-60011 (09316-00011, 09316-00031), 09950-60020 (09951-00890)

Fig 2: Installing Bearing Race For Output Shaft Using SST & Press

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Using SST and a press, install the bearing race.

1. SST 09316-60011 (09316-00011, 09316-00031), 09950-60020 (09951-00790)
Fig 3: Installing Bearing Race For Idler Gear Using SST & Press
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Install the oil receiver and bolt.

1. Torque: 12 N.m (120 kgf.cm, 9 ft.lbf) 

Fig 4: Installing Oil Receiver & Bolt To Front Case

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1. Install the shift inner lever, washer and outer lever to the front case.
2. Using a pin punch, hammer and socket wrench, tap in the lever lock pin.
3. Install the washer and nut to the shift outer lever.
   1. Torque: 12 N.m (120 kgf.cm, 9 ft.lbf) 
   Fig 5: Installing Lever Lock Pin Using Pin Punch, Hammer & Socket Wrench

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1. Assemble the shift fork No. 1 and shift fork No. 1 shaft.
2. Using a pin punch and hammer, drive in the slotted spring pin.
   Fig 6: Driving Slotted Spring Pin Using Pin Punch & Hammer

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1. Apply FIPG to the front case.
   1. FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent 
   Fig 8: Applying FIPG To Front Case
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2. Assemble the front case and rear case.
3. Apply liquid sealer to the "A"bolt threads.
   1. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 
4. Install the 8 bolts.
   1. Torque: 37 N.m (380 kgf.cm, 27 ft.lbf) 
   Fig 9: Installing Bolts

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Using a snap ring expander, install the snap ring to the rear case.

Fig 10: Installing Snap Ring To Rear Case Using Snap Ring Expander

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1. Apply FIPG to the rear case.
   1. FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent 
2. Install the case cover.
   Fig 11: Installing Rear Case Cover

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3. Apply liquid sealer to the bolt threads.
   1. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 
4. Install the 5 bolts.
   1. Torque: 37 N.m (380 kgf.cm, 27 ft.lbf) 
   Fig 12: Installing Bolts

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Install the oil strainer and 2 bolts.

1. Torque: 4.9 N.m (50 kgf.cm, 43 in.lbf) 

Fig 13: Installing Oil Strainer & Bolts

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1. Using vernier calipers, measure dimension "A".
2. Lightly hole down the bearing outer race in the thrust direction to eliminate any looseness before making the measurement.
   Fig 14: Measuring Dimension "A"

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3. Using a steel straight edge and feeler gauge, measure the clearance of dimension "B".
4. Calculate the required thickness of the adjusting shim.
   1. Thickness: Dimension "A"+ Dimension "B"+ [0.022 - 0.049 mm, (0.0009 - 0.0019 in.)] 
   Fig 15: Measuring Clearance Of Dimension "B"

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5. From Fig 16, select a shim so that its thickness is within the range of the calculation.
   Fig 16: Shim Thickness Specification Table

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1. Using a steel straight edge and feeler gauge, measure the clearance of dimension "C".
2. Lightly hold down the bearing outer race in the thrust direction to eliminate any looseness before making the measurement.
   Fig 17: Measuring Clearance Of Dimension "C"

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3. Using a steel straight edge and vernier calipers with depth gauge, measure dimension "D".
4. Dimension "D" is the straight edge thickness (Dimension "F") subtracted from dimension "E" in Fig 18 .
   1. Dimension "D": Dimension "E"- Dimension "F" 
   Fig 18: Measuring Dimension "D", "E" & "F"

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5. Using a steel straight edge and vernier calipers with depth gauge, measure dimension "G".
6. Dimension "G"is the straight edge thickness (Dimension "F") subtracted from Dimension "H".
   1. Dimension "G": Dimension "H"- Dimension "F" 
   Fig 19: Measuring Dimension "G", "H" & "F"

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7. Calculate the required thickness of the adjusting shim.
   1. Thickness: Dimension "G"- (Dimension "D"- Dimension "C") + [0.014 ~ 0.039 mm, (0.0006 ~ 0.0015 in.)] 
8. From Fig 20, select a shim so that its thickness is within the range of the calculation.
   Fig 20: Shim Thickness Specification Table

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1. Apply FIPG to the rear extension housing.
   1. FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent 
   Fig 21: Applying FIPG To Rear Extension Housing

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2. Install the rear extension housing and 9 bolts.
   1. Torque: 37 N.m (380 kgf.cm, 27 ft.lbf) 
   Fig 22: Installing Rear Extension Housing & Bolts

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1. Install the shift fork No. 2 to the shift fork No. 2 shaft.
2. Install the 3 snap rings to the shift fork No. 2 shaft.

HINT:

Make sure to install the clutch sleeve in the correct direction.

Fig 23: Installing Clutch Sleeve With Shift Fork

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1. Apply FIPG to the front extension housing.
   1. FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent 
   Fig 24: Applying FIPG To Front Extension Housing
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2. Install the front extension housing and 6 bolts.
   1. Torque: 37 N.m (380 kgf.cm, 27 ft.lbf) 
   Fig 25: Installing Front Extension Housing & Bolts
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   HINT:

   Set the clutch sleeve in differential lock condition.

Install the 3 transfer indicator switches with 3 new gaskets.

1. Torque: 37 N.m (380 kgf.cm, 27 ft.lbf) 

1. Install the ball and spring.
2. Apply liquid sealer to the screw plug threads.
   1. Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 
3. Using a torx socket wrench (T40), install the screw plug.
   1. Torque: 19 N.m (190 kgf.cm, 14 ft.lbf) 
   Fig 26: Installing Ball, Spring & Screw

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HINT:

Apply gear oil to the output gear.