MANUAL TRANSMISSION AND DIFFERENTIAL(5MT) > Transfer Case and Extension Case Assembly
ASSEMBLY
1. EXTENSION CASE
1. Using the ST, install the oil seal to the extension case. Oil Seal">
NOTE:
Use a new oil seal.
2. Install the dust cover.
3. Install the shift bracket.
Tightening torque:
24.5 N·m (2.5 kgf-m, 18.1 ft-lb)
4. Install the transfer drive gear to the extension case. Transfer Drive Gear > INSTALLATION">
2. TRANSFER CASE
1. Set the ST1, ST2, iron plate and the transfer case to the press.
NOTE:
• Set the ST2 under ST1.
• Set the transfer case so that the hole for shifter arm is positioned vertically.
• Insert the iron plate which is thicker than the exposed length of the transfer case knock pin between the ST and transfer case.
• Set the iron plate so that the transfer case knock pin does not ride on the iron plate.
ST1 498267300 | CYLINDER HEAD TABLE |
ST2 498267200 | CYLINDER HEAD TABLE |
(A) | Iron plate |
2. Press-fit the roller bearing using the ST.
Press-fit depth of roller bearing:
A: 0±0.2 mm (0±0.01 in) from the end of transfer case
ST 899864100 | REMOVER |
3. Remove the iron plate, and turn over the transfer case.
NOTE:
Set the transfer case so that the hole for shifter arm is positioned vertically.
4. Press-fit the roller bearing using the ST.
Press-fit depth of roller bearing:
A: 0±0.2 mm (0±0.01 in) from the end of transfer case
ST 899864100 | REMOVER |
5. Install the shifter arm to the transfer case, and make sure that the shift arm moves smoothly.
6. Install the oil guide.
NOTE:
Use a new installing bolt.
Tightening torque:
6.4 N·m (0.7 kgf-m, 4.7 ft-lb)
7. Install the reverse check sleeve assembly to the transfer case. Reverse Check Sleeve > INSTALLATION">
8. Install the oil seal.
NOTE:
Use a new oil seal.
Press-fit depth of oil seal:
A: 1±0.2 mm (0.04±0.01 in) from the end of transfer case
Assembly
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Removal
IGNITION(H4DO) > Spark PlugREMOVALSpark plug:Refer to “SPECIFICATION” for spark plug. General Description > SPECIFICATION">1. RH SIDE1. Disconnect the ground cable from battery. NOTE">2. Remove the air cleaner case. Air Cleaner Case > REMOVAL">3. Disco ...
Inspection
EyeSight > Relay and FuseINSPECTION1. CHECK FUSE1. Remove the fuse and inspect visually.2. If the fuse is blown out, replace the fuse.NOTE:If the fuse is blown again, check the system wiring harness.2. CHECK RELAY1. Measure the resistance between relay terminals.Terminal No.Inspection conditionsS ...