Part 2

OVERHAUL Continued





49. INSTALL RING GEAR
a. Clean the contact surface of the ring gear and transfer ring gear mounting case.
b. Heat the ring gear in water and boil for 10 minutes.
c. Carefully remove the ring gear from the water.





d. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the transfer ring gear mounting case.
e. Install the 10 bolts.
Torque: 78 Nm (790 kgf-cm, 57 ft. lbs.)

NOTICE:
^ Tighten the bolts in diagonal order in splitting several times.
^ After the ring gear has well cooled down, tighten the bolts.
^ Make paint marks, etc. do the procedure while checking the bolts retightened.





50. INSTALL RING GEAR MOUNTING CASE BEARING
a. Using SST and a press, press the ring gear mounting case bearing RH inner race into the transfer ring gear mounting case.
SST 09950-60010 (09951-00420)
b. Install the ring gear mounting case bearing RH outer race to the transfer ring gear mounting case.
c. Apply gear oil to the ring gear mounting case bearing RH.





d. Using SST and a press, press the ring gear mounting case LH inner race into the transfer ring gear mounting case.
SST 09223-00010, 09726-40010
e. Install the ring gear mounting case plate washer to the case.

HINT: Use a new washer with the same thickness as the removed one when installation.





f. Using SST and a press, press the ring gear mounting case bearing LH outer race into the transfer case.
SST 09950-60010 (09951-00620), 09950-70010 (09951-07200)
g. Apply gear oil to the ring gear mounting case bearing.





51. INSTALL TRANSFER RING GEAR MOUNTING CASE
a. Apply gear oil to the transfer ring gear mounting case.
b. Install the transfer ring gear mounting case to the transfer case.





52. INSTALL TRANSFER OUTPUT SHAFT SPACER NO.1
a. To install a new transfer output shaft spacer No.1, align the cutouts on it with the hole of the transfer case as shown in the illustration.





53. INSTALL TRANSFER RING GEAR MOUNTING CASE WASHER NO.2
a. Using a brass bar and a hammer, install a new transfer ring gear mounting case washer No.2.

HINT: Install a new washer No.2 with the same thickness as the removed one.





54. INSTALL BEARING CAP
a. Install the bearing cap with the 2 bolts.
Torque: 63 Nm (644 kgf-cm, 47 ft. lbs.)





55. INSPECT BACKLASH
a. Place a dial gauge on the teeth surface on the ring gear vertically, check with fixing the driven pinion and moving the ring gear.
Backlash: 0.10 to 0.18 mm (0.0039 to 0.0071 inch)

NOTICE: Check at least 3 positions on the circumference of the ring gear.





b. If the backlash is not in the range of specified value, select the ring gear mounting case bearing LH side washer from the table and install it to meet the specified value.





Washer thickness: mm (in.)





56. INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVEN PINION
a. Coat 3 or 4 teeth at the 4 different positions on the ring gear with red read.





b. Rotate the ring gear, inspect the teeth pattern.





c. If the teeth are not contacting properly, select the proper washer again.





Washer thickness: mm (in.)

NOTICE: When the board thickness is changed, readjust the back lash.





57. ADJUST MEASURE TOTAL PRELOAD
a. Using SST and a torque wrench, measure the total pre load.
SST 09326-20011
Total preload:
New bearing: Driven pinion preload + 0.30 to 0.45 Nm (3.0 to 4.6 kgf-cm, 2.6 to 4.0 inch lbs.)
Reused bearing: Driven pinion preload + 0.19 to 0.34 Nm (1.9 to 3.4 kgf-cm, 1.7 to 3.0 inch lbs.)





HINT:
^ Using a torque wrench with a fulcrum length of 160 mm (6 3 inch)
^ Turn the driven pinion counterclockwise and clockwise several times.

If the preload non-standard, again select proper washer.





Washer thickness: mm (in)





b. Using a chisel and a hammer, stake the gear nut.





58. INSTALL TRANSFER CASE RH OIL SEAL
a. Using SST and a hammer, drive a new transfer case RH oil seal into the case until it reaches the position shown in the illustration.
SST 09950-60010 (09951-00360, 09951-00590, 09952-06010), 09950-70010 (09951-07150)
Drive in depth: 33.7 to 34.3 mm (1.328 to 1.350 inch)

NOTICE: Do not install the oil seal at an angle.

b. Apply a little MP grease to the lip of the transfer case RH oil seal.





59. INSTALL TRANSFER CASE OIL SEAL
a. Using SST and a hammer, drive a new transfer case oil seal into the transfer case until the position in the illustration.
SST 09316-60011 (09316-00011)
Drive in depth: 9.7 to 10.3 mm (0.328 to 0.406 inch)

NOTICE: Do not install the oil seal at an angle.

b. Apply a little MP grease to the lip of the transfer case oil seal.





60. INSTALL TRANSFER EXTENSION HOUSING TYPE T OIL SEAL
a. Using SST and a hammer, drive a new transfer extension housing type T oil seal into the extension housing until the position in the illustration.
SST 09950-60010 (09951-00380, 09951-00580, 09952-06010), 09950-70010 (09951-07150)
Drive in depth: 1.1 to 1.9 mm (0.043 to 0.075 inch)
b. Apply a little MP grease to the lip of the transfer extension housing type T oil seal.





61. INSTALL TRANSFER EXTENSION HOUSING DUST DEFLECTOR
a. Using SST and a press, install the extension housing dust deflector to the transfer extension housing sub-assembly.
SST 09950-60010 (09951-00640), 09950-70010 (09951-07150)





62. INSTALL TRANSFER EXTENSION HOUSING SUB-ASSEMBLY
a. Remove any FIPG material and be careful not to drop oil on the contacting surfaces of the transfer extension housing sub-assembly and the transfer case.
b. Degrease the surface with white gasoline.
c. Apply FIPG to the transfer extension housing sub-assembly.
FIPG: Part No.08826-00090, THREE BOND 1281 or equivalent





d. Install the transfer extension housing sub-assembly with the 4 bolts to the transfer case.
Torque: 26 Nm (260 kgf-cm, 19 ft. lbs.)

NOTICE: Assemble transfer extension housing sub-assembly within 10 minutes after FIPG application.

63. SEPARATE TRANSFER ASSEMBLY
a. Remove the transfer assembly from the overhaul attachment.
64. INSTALL TRANSFER CASE STRAIGHT PIN





a. Using a plastic hammer, drive the 4 transfer case straight pins into the position in the illustration of the transfer case.





65. INSTALL TRANSFER DYNAMIC DAMPER
a. Install the transfer dynamic damper with the 3 bolts to the transfer extension housing sub-assembly.
Torque: 26 Nm (260 kgf-cm, 19 ft. lbs.)
66. INSTALL TRANSFER CASE BREATHER PLUG





67. INSTALL TRANSFER CASE COVER NO.1
a. Install the breather oil deflector with the bolt.
Torque: 6.5 Nm (66 kgf-cm, 58 inch lbs.)
b. Remove any FIPG material and be careful not to drop oil on the contacting surfaces of the transfer case cover No.1 and the transfer case.
c. Degrease the surface with white gasoline.
d. Apply FIPG to the transfer case cover No.1.
FIPG: Part No.08826-00090, THREE BOND 1281 or equivalent





e. Install the transfer case cover No.1 with the 8 bolts.
Torque: 20 Nm (200 kgf-cm, 14 ft. lbs.)

NOTICE:
^ Before pouring transfer oil, leave it at least an hour.
^ Assemble transfer case cover No.1 within 10 minutes after FIPG application.





68. INSTALL TRANSFER DRAIN PLUG
a. Install a new gasket to the transfer drain plug.
b. Install the transfer drain plug to the transfer assembly.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)





69. INSTALL TRANSFER CASE NO.1 PLUG
a. Install a new gasket to the transfer case No.1 plug.
b. Temporary tighten the transfer case No.1 plug to the transfer assembly.





70. INSTALL TRANSFER CASE NO.2 PLUG
a. Install a new gasket to the transfer case No.2 plug.
b. Install the transfer case No.2 plug to the transfer assembly.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
71. INSTALL TRANSFER & TRANSAXLE SETTING STUD BOLT
a. Install the 4 transfer & transaxle setting stud bolts to the position in the illustration of the transfer case.
Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)





HINT: In the case of this transfer & transaxle setting stud bolts in the illustration, the bottom side is the transfer case installation side.

Stud bolt length:
a: 30 mm (1.1811 inch)
b: 12 mm (0.4724 inch)
c: 22 mm (0.8661 inch)
72. INSTALL TRANSFER ASSEMBLY
a. Install the transfer assembly with the 6 nuts to the transaxle assembly.
Torque: 69 Nm (700 kgf-cm, 51 ft. lbs.)

NOTICE:
^ Install the transfer assembly to the transaxle assembly horizontally.
^ Do not touch the oil seal part of the transfer assembly when installation.





73. INSTALL TRANSFER STIFFENER PLATE RH
a. Install the transfer stiffener plate RH with the 4 bolts.
Torque: 34 Nm (347 kgf-cm, 25 ft. lbs.)
74. INSTALL TRANSFER STIFFENER PLATE CENTER
a. Install the transfer stiffener plate center with the 5 bolts.
Torque: 34 Nm (347 kgf-cm, 25 ft. lbs.)





75. INSTALL ENGINE MOUNTING BRACKET RR
a. Install the engine mounting bracket RR with the 3 bolts.
Torque: 64 Nm (652 kgf-cm, 47 ft. lbs.)
76. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH
77. INSTALL EXHAUST MANIFOLD
78. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1
79. INSTALL OXYGEN SENSOR
80. INSTALL MANIFOLD STAY
81. INSTALL FRONT SUSPENSION CROSSMEMBER W/CENTER MEMBER
82. INSTALL RACK & PINION POWER STEERING GEAR ASSEMBLY
SST 09023-38201
83. INSTALL VANE PUMP ASSEMBLY
84. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
SST 09670-00010
85. ADD TRANSFER OIL
Oil grade: API GL-5 L-5
Viscosity: SAE 90
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
86. ADD AUTOMATIC TRANSAXLE FLUID
87. ADD ENGINE OIL
88. ADD COOLANT
89. CHECK FOR ENGINE OIL LEAKS
90. CHECK FOR ENGINE COOLANT LEAKS
91. CHECK FUEL LEAK
92. CHECK FOR EXHAUST GAS LEAKS
93. INSPECT CHECK IDLE SPEED AND IGNITION TIMING
SST 09843-18030, 09843-18040
94. INSPECT CO/HC
95. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
96. CHECK ABS SPEED SENSOR SIGNAL
a. ABS WITH EBD SYSTEM
b. ABS WITH EBD & BA & TRAC & VSC SYSTEM