FUSO

Group 24
Transfer

Pub.No. 00ELT0083
 GROUP 24 TRANSFER

SPECIFICATIONS............................................................................... 24-2

STRUCTURE AND OPERATION

1. Transfer ........................................................................................ 24-3
2. Speedometer Gear Bushing .......................................................... 24-4

TROUBLESHOOTING ........................................................................ 24-5

ON-VEHICLE INSPECTION AND ADJUSTMENT

1. Inspection of Transmission and Transfer Oil Leakage .................. 24-6
2. Inspection of Looseness in Transmission and
Transfer Mounting Bolts ............................................................... 24-6
3. Inspection of Play and Looseness in Companion Flange .............. 24-6
4. Inspection and Replacement of Transfer Oil ................................. 24-7

REMOVAL AND INSTALLATION OF TRANSMISSION

(WITH TRANSFER)............................................................................. 24-8

REMOVAL AND INSTALLATION OF TRANSFER........................... 24-12

FRONT DRIVE .................................................................................. 24-14

REAR DRIVE..................................................................................... 24-20

TRANSFER ....................................................................................... 24-24

24-1
SPECIFICATIONS
Item Specifications
Model TF3
Transfer type Part-time
Drive type Gear
High 1.090
Gear ratio
Low 1.987
General: API GL-3 SAE 80
Gear oil Warm region: API GL-3 SAE 90
Transfer oil Tropical region: API GL-4 SAE 90
Oil quantity L Approx. 3.1
Mass (including transmission body) kg Approx. 165
Control Electric and vacuum type
• Transfer oil depends on the driving conditions.

24-2
STRUCTURE AND OPERATION 24
1. Transfer

• The transfer has two functions of distribution of all-wheel drive and a sub transmission with a reduction gear.
• The transfer is of a three-shaft constant-mesh type.
• The switch of a driver seat enables switching between the high and low range and engagement and disengage-
ment of the front drive.

24-3
STRUCTURE AND OPERATION
2. Speedometer Gear Bushing
• The speedometer gear bushing is eccentric, and displacing the
installed position allows it to correspond to the different number
of teeth of the speedometer gear.
• The numbers marked on the front at four locations show the
range of the number of teeth of the corresponding speedometer
gear.
“15-17”: Number of teeth 15 to 17.
• An identification mark showing the number of teeth is marked on
the speedometer gear.

Identification mark A B C D L E
Number of tooth 15 16 17 18 19 20
Gear ratio 3.0 3.2 3.4 3.6 3.8 4.0

24-4
TROUBLESHOOTING 24
Symptoms

Gears cannot be engaged when switching between high and low gear
Gears slip out of engagement during driving with front drive engaged

Gears cannot be disengaged when switching between high and low

Gears cannot be disengaged when switching to front drive
Gears cannot be engaged when switching to front drive

Indicator does not light though front drive is engaged

Indicator does not light though low gear is engaged
Indicator lights though front drive is not engaged
Indicator lights though low gear is not engaged
Gears slip out of engagement during driving
Noise when cruising
Possible causes
Front drive shaft and spline of constant sleeve worn O
Hub and spline of high and low constant sleeve worn O
Transfer idler bearing worn or damaged O
Transfer drive gear bearing worn or damaged O
Transfer driven rear shaft bearing worn or damaged O
Transfer driven rear shaft needle bearing worn or
O
damaged
Transfer body faulty
Gears damaged O
Backlash of low gear and high gear of driven shaft
O
excessive
Transfer oil insufficient O
Transfer oil viscosity inadequate O
Constant sleeve and dog clutch broken O O
High and low constant sleeve and hub broken O O
Shift rail bent O O
Shift rail sliding movement faulty O O
Shift fork bent O O
Control mechanism faulty
Shift fork claws worn O O
Steel ball and groove of shift rail poppet worn O
Poppet spring fatigued or damaged O
Transfer low switch faulty O O
Transfer four-wheel drive switch faulty O O
Blowout of fuse and high-current fuse O O O O
Transfer control system Battery overcharge O O
faulty 3-way magnet valve faulty O O O O O
Broken wire, poor connection O O
Air leakage in vacuum piping O O O
Vacuum actuator faulty O O O O O

24-5
ON-VEHICLE INSPECTION AND ADJUSTMENT
1. Inspection of Transmission and Transfer Oil Leakage
1.1 Inspection of oil leakage at each part of transmis-
sion body and transfer
• Check the oil leakage at each part of transmission body and
transfer in visual.
If the oil leakage is found, replace the defective part.
1.2 Inspection of oil leakage around transmission
mounting part
• Check there is not oil stain on transmission mounting part
caused by oil leakage from engine.
• If there is the oil stain, remove the transmission and clean the
mounting surface of clutch housing and flywheel housing using
brake cleaner etc. after repairing oil leakage part. Because the
oil stain may loosen the transmission mounting bolts. (See “RE-
MOVAL AND INSTALLATION OF TRANSMISSION (WITH
TRANSFER)”.)

2. Inspection of Looseness in Transmission and Transfer Mounting Bolts

Tightening torque (Unit: N·m {kgf·m})
Mark Parts to be tightened Tightening torque Remarks
– Bolt A (transfer mounting) 44.5 {4.5} –
M10 47.1 {4.8} –
– Bolt B (transmission mounting)
M12 82.4 {8.4} –

• Check the transmission and transfer mounting bolts for loose-

ness.
• Retighten any loose bolt to the specified torque.

3. Inspection of Play and Looseness in Companion Flange

• Check the propeller shaft mounting bolts for looseness. (See
Gr25.)
• Move the parking brake drum (on the rear drive side) and the
companion flange (on the front drive side) in axial and vertical di-
rections to check for excessive play between the companion
flange and the shaft.
• If excessive play is detected, remove the propeller shaft, then
check the lock nut for looseness and the splines on companion
flange and shaft for abnormalities. If any part is found defective,
replace the part. (See “FRONT DRIVE” and “REAR DRIVE” sec-
tions.)

24-6
 24
4. Inspection and Replacement of Transfer Oil
WARNING
• Temperature of transfer oil is high immediately after driving. Perform work when oil is cold.

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Inspection plug
– 68.6 ± 14.7 {7.0 ± 1.5} –
Drain plug (magnet type)

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Thread area of inspection plug
– ThreeBond 1105 As required
Thread area of drain plug
General: API GL-3 SAE 80
Approx. 3.1 dm3
– Transfer case Warm region: API GL-3 SAE 90
{3.1 L}
Tropical region: API GL-4 SAE 90
• Oil depends on the driving conditions.

[Inspection]
(1) Inspection of oil quantity
• Remove the inspection plug, and check that transfer oil is filled
up to the neck.
• If oil is not sufficient, fill oil from the inspection plug hole up to the
neck.
• After filling, apply sealant to the inspection plug and tighten it to
the specified torque.

(2) Inspection of oil quality and inclusions

• When draining transfer oil, check for oil quality, metal chips and
metal powder.
• If an abnormally large amount of metal chips and metal powder
is found, disassemble the transfer assembly for service, as ab-
normalities may be caused inside.

[Replacement]
• Remove the drain plug to drain transfer oil. Drainage can be
made quickly with the inspection plug removed.
• After draining transfer oil, apply sealant to the drain plug and
tighten it to the specified torque. Magnet type drain plug should
be cleaned before installation.
• Fill transfer oil in the specified quantity from the inspection plug
hole.
• After filling, wait for 1 minute or more to check that oil is filled up
to the neck of the inspection plug hole by inserting a finger to the
inspection plug hole. If oil is not sufficient, replenish it.
• After completing work, apply sealant to the inspection plug and
tighten it to the specified torque.

24-7
REMOVAL AND INSTALLATION OF TRANSMISSION (WITH TRANSFER)
Removal sequence
1 Propeller shaft (See Gr25.)
2 Clutch hose (See Gr21.)
3 Parking brake cable (See Gr36.)
4 Roll stopper bracket
5 Transmission

• When the oil stain is found inside of

clutch housing after removing the
transmission, check the oil leakage
portion of transmission or engine and
replace the defective part.

Installation sequence
Follow the removal sequence in reverse.

• Check and adjust the parking brake le-

ver after the installation. (See Gr36.)

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Bolt (transmission mounting) 45 to 65 {4.6 to 6.6} –
M10 47.1 {4.8} –
Bolt (transmission mounting)
M12 82.4 {8.4} –
Nut (roll stopper bracket mounting) 38 to 54 {3.9 to 5.5} –

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Molybdenum disulfide grease
Drive pinion spline As required
[NLGI No. 2 (Li soap)]
Mating surface of clutch housing and engine ThreeBond 1215 As required

24-8
 24
Removal procedure
Removal: Transmission
• Support the transmission on the transmission jack and remove
transmission mounting bolts.

• Insert a screwdriver into the three removal grooves and pry the
transmission from the engine.
• Move the transmission backward until the spline of the drive pin-
ion is detached from the clutch.
CAUTION
• Make sure that you pull the transmission out in a straight
line. If you seesaw the transmission violently, you will dam-
age the spline that connects the drive pinion and the clutch.

Installation procedure
Installation: Transmission
• Check the spline of the drive pinion for rust.
• If rust is found, remove it using a wire brush.
• Rub grease evenly onto the clutch disc sliding surface of the
drive pinion using your hand.
CAUTION
• Make sure that you apply only the necessary amount of
grease because too much grease would drip and cause
clutch slip.

[Applying sealant]
㻯㼘㼡㼠㼏㼔㻌㼔㼛㼡㼟㼕㼚㼓 • Apply sealant following manners shown below.
CAUTION
㻿㼑㼍㼘㼍㼚㼠 • Take care not to apply sealant under any of the following
conditions. Otherwise it causes water infiltration.
• There is dust, oil, grease, etc. on the mating surface.
• The diameter or thickness of the applied sealant is ex-
tremely different at each part.
㼣㼍㼠㼑㼞㻌㼐㼞㼍㼕㼚㻌㼔㼛㼘㼑 • The applied sealant has some breaks.
㻼㻡㻜㻝㻠㻥㻡㻱 • The applied sealant covers the water drain hole of the
clutch housing and engine parts.

<Case of using nozzle gun>

• Clean the mating surfaces of each part.
• Apply sealant on the width center of the mating surfaces so that
the diameter of the applied sealant is the same as the diameter
of the nozzle. The line of applying sealant is illustrated.

<Case of using spatula, etc.>

• Clean the mating surfaces of each part.
• Apply sealant evenly on the entire mating surfaces.

24-9
REMOVAL AND INSTALLATION OF TRANSMISSION (WITH TRANSFER)
[Installation]
• After applying the sealant, install the transmission before the
sealant dries. Be sure not to allow the sealant to be displaced.
• Do not start the engine within one hour after installing the trans-
mission.
• When loosing or removing transmission mounting bolts, be sure
to reapply the sealant.

• Support the transmission on the transmission jack, and insert

the transmission into the pilot bearing of the flywheel paying at-
tention to the drive pinion spline.
• Tighten transmission mounting bolts to the specified torque.

24-10
 24
M E M O

24-11
REMOVAL AND INSTALLATION OF TRANSFER

CAUTION
• Do not shake the transmission vio-
lently when removing the transfer
from it, as doing so may damage
the mainshaft end and gears.

NOTE
• The lock nut does not need to be re-
moved if the transfer alone is re-
moved.

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Bolt (transfer mounting) 44.5 {4.5} –
Lock nut 490 ± 49 {50 ± 5} –

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Transmission mounting surface of transfer ThreeBond 1215 As required

Special tools (Unit: mm)

Mark Tool name and shape Part No. Application

Socket wrench
MH063006 Removal and installation of lock nut
A
60

Installation procedure
Installation: Transfer
[Applying sealant]
• Apply sealant following manners shown below.
CAUTION
• Take care not to apply sealant under any of the following
conditions. Otherwise it causes oil leak.
• There is dust, oil, grease, etc. on the mating surface.
• The diameter or thickness of the applied sealant is ex-
tremely different at each part.
• The applied sealant has some breaks.

24-12
 24
<Case of using nozzle gun>
• Clean the mating surfaces of each part.
• Apply sealant on the width center of the mating surfaces so that
the diameter of the applied sealant is the same as the diameter
of the nozzle. The line of applying sealant is illustrated.

<Case of using spatula, etc.>

• Clean the mating surfaces of each part.
• Apply sealant evenly on the entire mating surfaces.

[Installation]
• After applying the sealant, install the transfer before the sealant
dries. Be sure not to allow the sealant to be displaced.
• Do not start the engine within one hour after installing the trans-
fer.
• When loosing or removing transfer mounting bolts, be sure to re-
apply the sealant.

24-13
FRONT DRIVE

24-14
 24
Disassembly sequence
1 Inspection plug 16 Steel ball 31 Lug spring retainer
2 Drain plug 17 O-ring 32 Shift lug spring
3 Clevis pin 18 Companion flange 33 Front drive shift fork
4 Transfer gear shift lever 19 Plug 34 Synchronizer sleeve
5 Shift lever bracket 20 Plug 35 Snap ring
6 Clevis pin 21 Set bolt 36 Snap ring
7 Vacuum actuator 22 Screw plug 37 Front drive hub
8 Shift rod 23 Interlock ball 38 Snap ring
9 Oil seal 24 Dust plug 39 Transfer
10 Shift rod bracket 25 Front drive shaft (See later section.)
11 Actuator bracket 26 Snap ring
12 Transfer high and low switch 27 Bearing : Non-reusable parts
13 Transfer four-wheel drive switch 28 Oil seal : Locating pin
14 Screw plug 29 Front drive case cover
15 Poppet spring 30 Snap ring

Assembly sequence
Follow the disassembly sequence in reverse except for the following.
22→33→24

Service standards (Unit: mm)

Location Maintenance item Standard value Limit Remedy
7 Airtightness of vacuum actuator 63.3 kPa {475 mmHg} – Replace
81 ± 8.14 N 65 N
15 Poppet spring installed load (installed length 22) Replace
{8.3 ± 0.83 kgf} {6.6 kgf}
22 ± 2.26 N 18 N
32 Shift lug spring installed load (installed length 20.6) Replace
{2.2 ± 0.23 kgf} {1.8 kgf}
Clearance between front drive shift fork and synchroniz-
33, 34 0.3 to 0.5 1.0 Replace
er sleeve

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Bolt (shift rail cover mounting)
44.5 {4.5} –
Bolt (front drive case cover mounting)
Transfer high and low switch
Transfer four-wheel drive switch 34.3 ± 4.9 {3.5 ± 0.5} –
Plug
Screw plug 39.2 {4} –
Lock nut 294 ± 49 {30 ± 5} –
After tightening,
Set bolt 29.4 {3} caulk it at three
locations.
Inspection plug
68.6 ± 14.7 {7.0 ± 1.5} –
Drain plug

24-15
FRONT DRIVE
Lubricant and/or sealant
Mark Points of application Specified lubricant and/or sealant Quantity
Both ends and fulcrum of transfer gear shift lever Wheel bearing grease
As required
Lip area of oil seal [NLGI No. 2 (Li soap)]
Transfer mounting surface of shift lever bracket
Thread area of screw plug ThreeBond 1215 As required
Transfer mounting surface of front drive case cover
Thread area of inspection plug
ThreeBond 1105 As required
Thread area of drain plug

Special tools (Unit: mm)

Mark Tool name and shape Part No. Application

Oil seal installer

MH061923 Installation of oil seal
A B C
φ35 φ15.5 9

Bearing installer
MB999104
A B
φ52 φ42

Installation of oil seal

Differential bearing in-
ner race installer
adapter
MB999105
A B
φ88 φ50

Snap ring expander MH061268 Removal and installation of snap ring

Flange puller
MH061848 Removal of companion flange
A B C
φ95 φ100 φ90

24-16
 24
Removal procedure
Removal: Companion flange
㻯㼛㼙㼜㼍㼚㼕㼛㼚㻌㼒㼘㼍㼚㼓㼑

㻼㼞㼛㼜㼑㼘㼘㼑㼞㻌㼟㼔㼍㼒㼠
㼙㼛㼡㼚㼠㼕㼚㼓㻌㼚㼡㼠
㻼㻝㻝㻜㻞㻤㻢㻱

Removal: Front drive case cover

• After removing the plug and set bolt, pull the high and low shift
rail toward the parking brake side until the rail stops (the rail
moves to the illustrated position) and remove the front drive
case cover.
NOTE
• Be careful that the interlock balls may fall when the front
drive case cover is removed.

Inspection procedure
Inspection: Vacuum actuator
• Pipe the vacuum pump, check valve and vacuum gauge, apply
negative pressure of 66.7 kPa {500 mmHg} to the vacuum actu-
ator, and stop the vacuum pump. After 15 seconds, measure the
negative pressure with the vacuum gauge.
• If the measured value deviates from the standard value, replace
the vacuum actuator.

Inspection: Clearance between front drive shift fork and

synchronizer sleeve
• If the measurement exceeds the limit, replace defective parts.

24-17
FRONT DRIVE
Installation procedure
Installation: Oil seal
• Apply grease to the lip area of the oil seal and install it on the
front drive case cover in the illustrated direction.

Installation: Front drive case cover

[Applying sealant]
• Apply sealant following manners shown below.
CAUTION
• Take care not to apply sealant under any of the following
conditions. Otherwise it causes oil leak.
• There is dust, oil, grease, etc. on the mating surface.
• The diameter or thickness of the applied sealant is ex-
tremely different at each part.
• The applied sealant has some breaks.

<Case of using nozzle gun>

• Clean the mating surfaces of each part.
• Apply sealant on the width center of the mating surfaces so that
the diameter of the applied sealant is the same as the diameter
of the nozzle. The line of applying sealant is illustrated.

<Case of using spatula, etc.>

• Clean the mating surfaces of each part.
• Apply sealant evenly on the entire mating surfaces.

[Installation]
• After applying the sealant, install the front drive case cover be-
fore the sealant dries. Be sure not to allow the sealant to be dis-
placed.
• Do not start the engine within one hour after installing the front
drive case cover.
• When loosing or removing front drive case cover mounting bolts,
be sure to reapply the sealant.

Installation: Interlock ball

• Install the front drive case cover on the transfer.
• Push in the high and low shift rail to the illustrated position (until
the hole in which the balls enter is visible from the dust plug
hole), and roll in the interlock balls from the dust plug to install.

24-18
 24
Installation: Oil seal
• Apply grease to the lip area of the oil seal and install it in the il-
lustrated direction.

24-19
REAR DRIVE

Disassembly sequence
1 Plate 13 Speedometer joint
2 Idler rear cover 14 Speed drive shaft
3 O-ring 15 Spring pin
4 Shim 16 Speedometer gear
5 O-ring 17 O-ring
6 Dust plug 18 Oil seal
7 Parking brake drum (See Gr36.) 19 Speedometer gear bushing
8 Companion flange 20 Air breather
9 Reamer bolt 21 Input rear cover
10 Parking brake (See Gr36.) 22 Transfer (See later section.)
11 Vehicle speed sensor
12 L-joint : Non-reusable parts

Assembly sequence
Follow the disassembly sequence in reverse.

Service standards (Unit: mm)

Location Maintenance item Standard value Limit Remedy
0 to 2 N·m
Startup torque of idler gear bearing (measure with tan- {0 to 0.2 kgf·m}
– gential force at outer diameter position of parking brake Tangential force: – Adjust or replace
drum) 0 to 26.9 N
{0 to 2.7 kgf}
8 Runout at socket portion of companion flange 0 to 0.15 0.15 Replace
Clearance between speedometer gear and speedome-
16, 19 0.04 to 0.09 0.15 Replace
ter gear bushing

24-20
 24
Tightening torque (Unit: N·m {kgf·m})
Mark Parts to be tightened Tightening torque Remarks
Bolt (idler rear cover mounting)
44.5 {4.5} –
Bolt (input rear cover mounting)
Lock nut 245 to 343 {25 to 35} –
Reamer bolt 52.0 to 66.7 {5.3 to 6.8} –
Vehicle speed sensor 14.7 to 29.4 {1.5 to 3} –
Bolt (speedometer gear bushing mounting) 23.5 {2.4} –
L-joint
34 to 49 {3.5 to 5.0} –
Speedometer joint

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Transfer mating surface of idler rear cover
ThreeBond 1215 As required
Transfer mating surface of input rear cover
Speedometer gear bushing sliding area of speedometer Molybdenum disulfide grease
As required
gear [NLGI No. 2 (Li soap)]
O-ring Wheel bearing grease
As required
Lip area of oil seal [NLGI No. 2 (Li soap)]

Special tools (Unit: mm)

Mark Tool name and shape Part No. Application

Flange puller
MH061848 Removal of companion flange
A B C
φ95 φ100 φ90

Work before removal

Alignment marks: Speedometer gear bushing
• The installed direction of the speedometer gear bushing is deter-
mined by the number of the speedometer gear tooth.
• Put alignment marks to prevent misassembly.

Inspection: Startup torque of idler gear bearing

• Measure the tangential force at the outer diameter of the parking
brake drum using a spring balance.

24-21
REAR DRIVE
Removal procedure
Inspection: Runout at socket portion of companion flange
• After removing the parking brake drum, measure the runout at
the socket portion of the companion flange.
• If the measurement exceeds the limit, replace the companion
flange.

Removal: Companion flange

Inspection procedure
Inspection: Clearance between speedometer gear and
speedometer gear bushing
• If the clearance exceeds the limit, replace speedometer gear
bushing.

Installation procedure
Installation: Speedometer gear bushing
• When replacing the speedometer gear bushing, align the align-
ment mark of the old part with that of the transfer to install.

Installation: Oil seal

• Apply grease to the lip area of the oil seal.
• Install the oil seal evenly in the illustrated direction using a round
bar of outer diameter of approx. 15 mm.

24-22
 24
Installation: Spring pin
• Install the spring pin in the speedometer gear bushing in the il-
lustrated direction.

Inspection after installation

Inspection: Starting torque of pinion bearing
• Measure the tangential force at the outer diameter of the parking
brake drum using a spring balance.
• If the tangential force meets the specified value, the startup
torque becomes the standard value.
• If the measured value deviates from the standard value, adjust
by changing thickness of the shim.
Kinds of shim: 0.10, 0.15, 0.20, 0.50 mm

24-23
TRANSFER

Disassembly sequence
1 Oil seal 11 Front drive shift rail
2 Oil seal 12 Speedometer worm
3 Oil seal 13 Pin
4 Transfer cover 14 Transfer driven rear shaft (See later section.)
5 Transfer idler gear (See later section.) 15 Oil gutter
6 Transfer drive gear (See later section.) 16 Oil seal
7 High and low shift fork 17 Transfer case
8 High and low shift rail
9 Set bolt : Locating pin
10 Shift rail stopper : Non-reusable parts

Assembly sequence
Follow the disassembly sequence in reverse.

24-24
 24
Service standards (Unit: mm)
Location Maintenance item Standard value Limit Remedy
Driven rear shaft low gear
– End play 0.25 to 0.40 0.6 Replace
Driven rear shaft high gear
7 Tilt of high and low shift fork claws 0 to 0.1 0.2 Replace
Clearance between high and low shift fork and synchro-
7, 14 0.3 to 0.5 1.0 Replace
nizer sleeve of transfer driven rear shaft
8, 11 Bend of shift rail 0 to 0.02 0.03 Replace

Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Bolt (transfer cover mounting) 44.5 {4.5} –
After tightening,
Set bolt 29.4 {3} caulk it at three
locations.

Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Transfer case mating surface of transfer cover ThreeBond 1215 As required
Wheel bearing grease
Lip area of oil seal As required
[NLGI No. 2 (Li soap)]

Special tools (Unit: mm)

Mark Tool name and shape Part No. Application

Oil seal installer

MH062691 Installation of oil seal
A B C
φ64 φ50 17

Oil seal installer

MH061923 Installation of oil seal
A B C
φ35 φ15.5 9

Work before removal

Inspection: End play of gears
• Measure the end play using feeler gauge.
• If the measurement exceeds the limit, replace defective parts.

24-25
TRANSFER
Inspection procedure
Inspection: Tilt of high and low shift fork claws
• Measure the tilt (difference between A and A’) of claw A–A’
against the high and low shift rail hole of high and low shift fork
with pressing the rail to V-block and standing it vertically.
• If the measurement exceeds the limit, replace the high and low
shift fork.

Inspection: Clearance between high and low shift fork and

synchronizer sleeve of transfer driven rear shaft
• If the measurement exceeds the limit, replace defective parts.

Inspection: Bend of high and low shift rail

• Measure the extent of bending at the middle of the high and low
shift rail.
• While rotating the high and low shift rail by one revolution, read
how much the dial gauge needle will move. A half of the reading
observed represents the bend, if any, of the shaft.
• If the measurement exceeds the limit, replace the high and low
shift rail.

Installation procedure
Installation: Oil seal
• Apply grease to the lip area of the oil seal and install it on the
transfer cover in the illustrated direction.

Installation: Oil seal

• Apply grease to the lip area of the oil seal and install it on the
transfer cover in the illustrated direction.

24-26
 24
Installation: Transfer cover
[Applying sealant]
• Apply sealant following manners shown below.
CAUTION
• Take care not to apply sealant under any of the following
conditions. Otherwise it causes oil leak.
• There is dust, oil, grease, etc. on the mating surface.
• The diameter or thickness of the applied sealant is ex-
tremely different at each part.
• The applied sealant has some breaks.

<Case of using nozzle gun>

• Clean the mating surfaces of each part.
• Apply sealant on the width center of the mating surfaces so that
the diameter of the applied sealant is the same as the diameter
of the nozzle. The line of applying sealant is illustrated.

<Case of using spatula, etc.>

• Clean the mating surfaces of each part.
• Apply sealant evenly on the entire mating surfaces.

[Installation]
• After applying the sealant, install the transfer cover before the
sealant dries. Be sure not to allow the sealant to be displaced.
• Do not start the engine within one hour after installing the trans-
fer cover.
• When loosing or removing transfer cover mounting bolts, be
sure to reapply the sealant.

24-27
TRANSFER
Transfer Idler Gear
Disassembly sequence
1 Transfer idler shaft
2 Bearing inner race
3 Bearing outer race
4 Transfer idler gear

Assembly sequence
Follow the disassembly sequence in re-
verse.

Removal procedure
Removal: Bearing outer race
• Evenly tap the bearing outer race to take it out from the transfer
idler gear.

24-28
 24
Transfer Drive Gear
Disassembly sequence
1 Bearing
2 Bearing
3 Plug
4 Transfer drive gear

Assembly sequence
Follow the disassembly sequence in re-
verse.

24-29
TRANSFER
Transfer Driven Rear Shaft

Disassembly sequence
1 Bearing 7 Bearing
2 Thrust washer 8 Thrust washer
3 Driven rear shaft low gear 9 Driven rear shaft high gear
4 Needle bearing 10 Needle bearing
5 Synchronizer sleeve 11 Needle bearing
6 Snap ring 12 Transfer driven shaft

• Do not remove the needle bearing marked with from the transfer driven rear shaft unless any abnormality is
found.

Assembly sequence
Follow the disassembly sequence in reverse.

Service standards (Unit: mm)

Location Maintenance item Standard value Limit Remedy
– Play in diameter direction of transfer driven rear shaft 0.02 to 0.06 0.12 Replace

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Special tools (Unit: mm)
Mark Tool name and shape Part No. Application

Snap ring expander MH061268 Removal and installation of snap ring

Needle roller bearing

installer
MH061927 Installation of needle bearing

A B C D E
φ18.5 φ13 φ40 15 28

Inspection before removal

Inspection: Play in diameter direction of driven rear shaft
gears
• If the measurement exceeds the limit, replace defective parts.

Installation procedure
Installation: Needle bearing

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