Shift Link Assembly

Shift Link Assembly

REMOVAL
1) Remove the manual transmission assembly from the vehicle.
2) Remove the back-up light switch neutral position switch.
3) Remove the transfer case together with the extension case assembly.
4) Remove the extension case assembly.
5) Pull out the straight pin.





6) Drive out the spring pin by tapping with the ST, and remove the select lever COMPL.
ST 398791700 SPRING PIN REMOVER 2





7) Pull out the selector arm No. 2 from neutral set spring.





8) Remove the shifter arm collar and neutral set spring from transfer case.





9) Remove the shifter arm No. 2, washers and thrust bearing from transfer case.





10) Drive out the spring pin by tapping with the ST, and remove the shifter arm and selector arm.
ST 398791700 SPRING PIN REMOVER 2





11) Remove the oil seal from transfer case using a screwdriver.

NOTE:
The illustration shows the oil seal of select lever COMPL. Perform the same procedures for removing the shifter arm No. 2.





12) Remove the needle bearing from the transfer case.

NOTE:
^ Use the round bar with diameter of 20 - 21 mm (0.79 - 0.83 in).
^ By pushing the flange surface (stamp mark side), press it into the transfer case to remove.





13) Remove the roll bearing from the transfer case.

NOTE:
Use the round bar with diameter of 22 - 23 mm (0.87 - 0.91 in).





14) Remove the plunger and check ball spring from transmission cover.





INSTALLATION
1) Install the plunger and check ball spring to transmission cover.

NOTE:
Use a new seal ring.





2) Install the needle bearing to the transfer case.

NOTE:
^ Use the round bar with diameter of 20 - 21 mm (0.79 - 0.83 in).
^ Press in by pushing the flange surface (stamp mark side).





3) Install the roll bearing to the transfer case.

NOTE:
Use the round bar with diameter of 22 - 23 mm (0.87 - 0.91 in).





4) Using the ST, install the oil seal to the transfer case.

NOTE:
^ Use a new oil seal.
^ The illustration shows the oil seal of selector lever COMPL. Perform the same procedures for installing the shifter arm No. 2.
^ Apply transmission gear oil to the oil seal lips.

Press-fit depth of oil seal.
-1.0 mm (-0.04 in) from the end of transfer case

ST 18657AA000 INSTALLER





5) Insert the shifter arm into selector arm, then fix with a spring pin using the ST.

NOTE:
Use new spring pin.

ST 398791700 SPRING PIN REMOVER 2





6) Install the shifter arm No. 2, washers and thrust bearing to transfer case.





7) Install the shifter arm collar and neutral set spring to transfer case.





8) Install the selector arm No. 2 to neutral set spring.





9) Insert the selector lever COMPL into selector arm No. 2, then fix with a spring pin using the ST.

NOTE:
Use new spring pin.

ST 398791700 SPRING PIN REMOVER 2





10) Insert a new straight pin.





11) Apply a proper amount of liquid gasket to the transmission cover mating surface.
Liquid gasket:
THREE BOND 1215 (Part No. 004403007) or equivalent





12) Install the transmission cover to transfer case.





13) Install the extension assembly to the transfer case.
14) Install the transfer case and the extension case assembly.
15) Install the back-up light switch neutral position switch.
16) Install the manual transmission assembly to the vehicle.