Upper cover and crankcase extension.
1 - bushing,
2 - control rod seal,
3 - oil seal of the crankcase extension,
4 - funnel,
5 - crankcase extension,
6 - sealing cover,
7 - transfer case,
8 - breather,
9 - breather boot,
10 - reversing light switch,
11 - neutral gear engagement sensor,
12 - speed sensor,
13 - all-wheel drive engagement sensor,
14 - steel ball,
15 - spring,
16 - sensor pin,
17 - transfer case neutral gear engagement sensor,
18 - gearbox control lever seat,
19 - transfer case control lever,
20 - gearbox control lever,
21 - bushing,
22 - washer,
23 - gasket,
24 - anther,
25 - control rod tip,
26 - oil drain,
27 - top cover,
28 - case,
29 - clutch release bearing,
30 - clutch release fork.
Notes on removal
1. Crankcase extension oil seal.
2. Top cover.
Using a slotted screwdriver positioned as shown in the figure, pry the top cover off and then remove it.
3. Crankcase extension.
Using a slotted screwdriver positioned as shown in the illustration, disconnect the crankcase extension and then remove it.
4. Control rod seal.
Using a slotted screwdriver, remove the oil seal.
5. Sealing cover.
Using drifts and a hammer, remove the sealing cover.
Note: Only remove the sealing cap if it is faulty and you intend to replace it.
6. Bushing.
Using a mandrel and a hammer, remove the bushings.
Front hub.
Rear hub.
Using a slotted screwdriver, remove the oil seal.
Installation Notes
1. Bushing.
Using drifts and a hammer, set the front and rear bushings to the specified depth.
Front hub.
Rear hub.
2. Control rod seal.
a) Apply grease to the sealing lip of the oil seal.
b) Using a drift and hammer, install the seal as shown in the figure.
3. Sealing cover.
Using drifts and a hammer, install the sealing cover as shown in the figure.
4. Crankcase extension seal.
a) Apply grease to the sealing lip of the oil seal.
b) Using mandrels and a hammer, install the seal as shown in the figure.
5. Crankcase extension.
a) Apply sealant to the contact surface of the housing extension and the gearbox housing.
b) Install the crankcase extension onto the gearbox.
- Tightening torque - 31 - 46 Nm
Note: Installation must be completed within 30 minutes after applying the sealant. Otherwise, remove the applied sealant and repeat the procedure again.
6. Top cover.
a) Apply sealant to the contact surface of the top cover as shown in the figure.
b) Install the top cover onto the gearbox.
- Tightening torque - 16 - 23 Nm
Note: Installation must be completed within 10 minutes after applying the sealant. Otherwise, remove the applied sealant and repeat the procedure again.
7. Sealing cover.
a) Apply sealant to the contact surface of the sealing cover as shown in the figure.
b) Install the sealing cover on the gearbox.
- Tightening torque: 8-10 Nm
Note: Installation must be completed within 10 minutes after applying the sealant. Otherwise, remove the applied sealant and repeat the procedure again.
8. Breather.
Install the breather using a mandrel and a hammer.
9. Clutch release fork and release bearing.
Before installing the clutch release fork and release bearing, apply grease to the surfaces shown in the figure.
