Transfer Case
2. TRANSFER CASEAssembly of transfer case is in the reverse order of disassembly. Do the following:
1) Assembly of reverse check sleeve
(1) Install reverse accent shaft (F), check cam (D), return spring (E) and check spring (C) onto reverse check sleeve.
NOTE: Be sure the bent section of reverse check spring is positioned in the groove in check cam.
(2) Hook the bent section of reverse check spring over reverse check plate (B).
(3) Rotate cam so that the protrusion of reverse check cam is at the opening in plate.
(4) With cam held in that position, install plate onto reverse check sleeve and hold with snap ring (A) (Inner-28).
(5) Position O-ring (G) (35.4 x 1.5) in groove in sleeve.
CAUTION:
- Make sure the cutout section of reverse accent shaft is aligned with the opening in reverse check sleeve.
- Spin cam by hand for smooth rotation.
If it does not return properly, replace reverse check spring.
- Move cam and shaft all the way toward plate and release.
If cam does not return properly, replace reverse check spring; if shaft does not, check for scratches on the inner surface of sleeve. If sleeve is in good order, replace spring.
- Select a suitable reverse accent shaft and reverse check plate by referring to "Neutral Position Adjustment."
2) Installation of shifter arm (1) and selector arm (8). Install shifter arm into the partition from the front while inserting selector arm into the opening in reverse check sleeve. Pass shaft through hole in selector arm until its end comes out of the rear of transfer case.
NOTE: Apply a coat of gear oil to shifter arm. Also make sure oil seal is positioned properly.
Tightening torque:
T1: 6.4 ± 0.5 N.m (0.65 ± 0.05 kg-m, 4.7 ± 0.4 ft-lb)
T2: 10 ± 1 N.m (1.0 ± 0.1 kg-m, 7.2 ± 0.7 ft-lb)
T3: 19.6 ± 1.5 N.m (2.00 ± 0.15 kg-m, 14.5 ± 1.1 ft-lb)
T4: 25 ± 2 N.m (2.5 ± 0.2 kg-m, 18.1 ± 1.4 ft-lb)