Input Shaft, Output Shafts (Driven Shafts), Differential, Bevel Gear Transfer Case and Shift Rods, Removing and Installing

Input shaft, output shafts (driven shafts), differential, bevel gear transfer case and shift rods (transmission as of approx. 04.2003), removing and installing, 02M/02Y, 5 & 6 Speed M/T, AWD





1 - Output shaft 1st to 4th gear
^ Installed position

2 - Shift rod with shift fork for 1st and 2nd gear
^ Installed position

3 - Shift rod with shift fork for 3rd and 4th gear
^ Installed position

4 - Output shaft 5th/6th and reverse gear
^ Installed position

5 - Shift rod with shift fork for 5th and 6th gear
^ Installed position

6 - Shift fork for reverse gear
^ Installed position

7 - Input shaft

8 - Reverse shaft

9 - Thrust washer

10 - Bleeder

11 - Bolt, 12 Nm
^ Self-locking
^ Replace

12 - Locking plate
^ Secures outer race for tapered roller bearing of input shaft

13 - Clutch housing

14 - Seal
^ For input shaft

15 - O-ring
^ Install on line connection
^ Coat with brake fluid before installing

16 - Clutch slave cylinder with release bearing

17 - Hex bolt, 12 Nm
^ Qty. 3
^ Replace

18 - Conical head bolt, 25 Nm
^ Length is matched to bevel gear transfer case
^ When replacing bevel gear transfer case

19 - O-ring
^ Replace

20 - Bevel gear transfer case

21 - Bolt, 40 Nm plus an additional 45° (1/8 turn)
^ Replace

22 - Washer

23 - O-ring
^ Replace

24 - O-ring
^ Replace

25 - Hex bolt, 12 Nm
^ Replace

26 - Not installed

27 - Not installed

28 - Differential





Installation position of shafts and shift rods in transmission
1 - Input shaft

2 - Output shaft 1st to 4th gear

3 - Output shaft for 5th/6th and reverse gear

4 - Reverse shaft

A- Selector rod for 3rd and 4th gear

B- Shift rod for 1st and 2nd gear

C- Shift rod for 5th and 6th gear

D- Shift fork for reverse gear