TRANSFER GI

SECTION TF MA

EM

LC

EC
CONTENTS
FE
PREPARATION................................................................2 Front Drive Shaft .......................................................20
Special Service Tools ..................................................2 Counter Gear .............................................................21
Commercial Service Tools ...........................................3 Main Gear ..................................................................21 CL
NOISE, VIBRATION AND HARSHNESS (NVH) Front Case .................................................................23
TROUBLESHOOTING .....................................................4 Shift Shaft Oil Seal................................................23
NVH Troubleshooting Chart.........................................4 Front Case Cover ......................................................23 MT
Transfer ...................................................................4 Cover Oil Seal.......................................................23
DESCRIPTION .................................................................5 Bearing Retainer........................................................24
Cross-sectional View ...................................................5 Oil Catcher ............................................................24 AT
ON-VEHICLE SERVICE ..................................................6 Center Case...............................................................24
Replacing Oil Seal .......................................................6 Removal ................................................................24
Center Case Oil Seal ..............................................6 Center case oil seal..........................................24
TF
Shift Shaft Oil Seal..................................................6 Installation .............................................................24
Rear Oil Seal...........................................................7 Center case oil seal..........................................24 PD
REMOVAL AND INSTALLATION ....................................8 Rear Case..................................................................24
TRANSFER GEAR CONTROL .......................................9 Rear Oil Seal.........................................................24
MAJOR OVERHAUL .....................................................10 Air Breather ...........................................................25 FA
Case Components .....................................................10 Shift Control Components .........................................25
Gear Components .....................................................11 ASSEMBLY....................................................................27
Shift Control Components .........................................12 SERVICE DATA AND SPECIFICATIONS (SDS) ..........34 RA
DISASSEMBLY..............................................................13 General Specifications...............................................34
REPAIR FOR COMPONENT PARTS............................18 Inspection and Adjustment ........................................34
Mainshaft ...................................................................18 BR

ST

RS

BT

HA

EL

IDX
 PREPARATION

Special Service Tools

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number
(Kent-Moore No.) Description
Tool name

ST38060002 Removing companion flange nut

(J34311) Installing companion flange nut
Flange wrench

a: 480 mm (18.90 in)

b: Pitch dia.: 75 mm (2.95 in)
NT428 Pin dia.: 10 mm (0.39 in)

ST30021000 Removing counter gear front bearing

(J22912-01) (Use with ST36710010)
Puller Removing L & H hub

a: 110 mm (4.33 in) dia.

NT411 b: 68 mm (2.68 in) dia.

ST30031000 Removing counter gear rear bearing

(J22912-01) (Use with ST36710010)
Puller

a: 90 mm (3.54 in) dia.

NT411 b: 50 mm (1.97 in) dia.

ST33290001 Removing center case oil seal

(J34286) Removing rear oil seal
Puller

a: 250 mm (9.84 in)

NT414 b: 160 mm (6.30 in)

ST33051001 Removing companion flange

(J22888)
Puller

a: 135 mm (5.31 in)

b: 100 mm (3.94 in)
NT657 c: 130 mm (5.12 in)

ST30720000 s
1 Installing center case oil seal
s1 (J25273) s
2 Installing rear oil seal
s2 (J25405)
Drift
a: 77 mm (3.03 in) dia.
NT115 b: 55.5 mm (2.185 in) dia.

ST36710010 Removing counter gear front bearing

( — ) (Use with ST30021000)
Drift Removing counter gear rear bearing
(Use with ST30031000)

NT063 a: 34.5 mm (1.358 in) dia.

TF-2
 PREPARATION
Special Service Tools (Cont’d)
GI
Tool number
(Kent-Moore No.) Description
Tool name
MA
ST33061000 Removing main gear bearing
(J8107-2)
Drift EM
a: 28.5 mm (1.122 in) dia.
NT116 b: 38 mm (1.50 in) dia.
LC
ST30613000 s
1 Installing main gear bearing
s1 (J25742-3) (Use with ST30611000)
s2 (J34339) s
2 Installing cover oil seal EC
Drift (Use with ST30611000)

a: 72 mm (2.83 in) dia.

NT073 b: 48 mm (1.89 in) dia.
FE
(J35864) Installing shift shaft oil seal
Drift CL
a: 26 mm (1.02 in) dia.
b: 20 mm (0.79 in) dia.
NT117 c: 150 mm (5.91 in) MT
(J26092) Seating counter gear assembly
Drift AT
a: 44.5 mm (1.752 in) dia.
NT065 b: 38.5 mm (1.516 in) dia.
TF
(J34291) Selecting counter gear rear bearing shim
Shim setting gauge set
PD

NT101 FA
(J34291-20) Selecting counter gear rear bearing shim
Plunger-shim setting gauge RA

NT118
BR

Commercial Service Tools ST

Tool name Description

Puller Removing front drive shaft front bearing RS

Removing front drive shaft rear bearing
Removing main gear bearing
Removing companion flange BT
NT077

Drift s
1 Installing mainshaft rear bearing HA
s
2 Installing L & H hub
s
1 a: 50 mm (1.97 in) dia.
b: 42 mm (1.65 in) dia. EL
c: 180 mm (7.09 in)
s2 a: 60 mm (2.36 in) dia.
b: 50 mm (1.97 in) dia. IDX
NT117 c: 60 mm (2.36 in)

TF-3
 Symptom
TRANSFER

Reference page

(Possible cause)

Noise
SUSPECTED PARTS

Fluid leakage

Jumps out of gear

Hard to shift or will not shift
If necessary, repair or replace these parts.

1
FLUID (Level low)
Refer to MA section (‘‘Checking Transfer

1
3
2
FLUID (Wrong) Fluid’’, ‘‘CHASSIS AND BODY MAINTE-
NANCE’’).

TF-4
1
1
FLUID (Level too high)

2
LIQUID GASKET (Damaged) TF-10

2
OIL SEAL (Worn or damaged) TF-10

1
CHECK SPRING AND CHECK BALL (Worn or damaged) TF-10, 12
NVH Troubleshooting Chart

2
SHIFT FORK (Worn) TF-12

2
3
GEAR (Worn or damaged) TF-11

3
BEARING (Worn or damaged) TF-11
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

2
BAULK RING (Worn or damaged) TF-11

2
SHIFTING INSERT (Damaged) TF-11
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of inspection.
 DESCRIPTION

Cross-sectional View GI

MA

EM

LC

EC

FE

CL

MT

AT

TF

PD

FA

RA

BR

ST

RS

BT

HA

EL

IDX

ATF006

TF-5
 ON-VEHICLE SERVICE

Replacing Oil Seal

CENTER CASE OIL SEAL
1. Remove front propeller shaft. Refer to PD section (‘‘Removal
and Installation’’, ‘‘PROPELLER SHAFT’’).
2. Remove companion flange nut.

SMT485A

3. Remove companion flange.

SMT486A

4. Remove center case oil seal.

5. Install center case oil seal.
● Before installing, apply multi-purpose grease to seal lip.
6. Install companion flange.

AMT086

7. Tighten companion flange nut.

: 226 - 324 Nzm (23 - 33 kg-m, 166 - 239 ft-lb)
8. Install front propeller shaft. Refer to PD section (‘‘Removal and
Installation’’, ‘‘PROPELLER SHAFT’’).

SMT489A

SHIFT SHAFT OIL SEAL

1. Remove front propeller shaft. Refer to PD section (‘‘Removal
and Installation’’, ‘‘PROPELLER SHAFT’’).
2. Remove companion flange. Refer to ‘‘CENTER CASE OIL
SEAL’’, above.
3. Remove transfer control lever from transfer outer shift lever.
Then remove outer shift lever.

ATF007

TF-6
 ON-VEHICLE SERVICE
Replacing Oil Seal (Cont’d)
4. Remove shift shaft oil seal. GI
● Be careful not to damage cross shaft.
MA

EM

LC
SMT491A

5. Install shift shaft oil seal. EC

● Before installing, apply multi-purpose grease to seal lip.
6. Install transfer control linkage.
FE
7. Install companion flange. Refer to ‘‘CENTER CASE OIL
SEAL’’, TF-6.
8. Install front propeller shaft. Refer to PD section (‘‘Removal and
Installation’’, ‘‘PROPELLER SHAFT’’).
CL

MT
SMT492A

REAR OIL SEAL AT

1. Remove rear propeller shaft. Refer to PD section (‘‘Removal
and Installation’’, ‘‘PROPELLER SHAFT’’). TF
2. Remove rear oil seal.

PD

FA
AMT087

3. Install rear oil seal. RA

● Before installing apply multi-purpose grease to seal lip.
4. Install rear propeller shaft. Refer to PD section (‘‘Removal and BR
Installation’’, ‘‘PROPELLER SHAFT’’).

ST

RS
SMT494A
BT

HA

EL

IDX

TF-7
REMOVAL AND INSTALLATION

Removal
1. Drain oil from transfer and transmission.
2. Remove front and rear propeller shaft. Refer to PD section
(‘‘Removal and Installation’’, ‘‘PROPELLER SHAFT’’).
Insert plug into rear oil seal after removing propeller shaft.
● Be careful not to damage spline, sleeve yoke and rear oil
seal, when removing propeller shaft.
3. Remove torsion bar spring. Refer to FA section (‘‘Torsion Bar
Spring’’, ‘‘FRONT SUSPENSION’’). Then remove second
crossmember.
ATF020
4. Remove exhaust front and rear tubes. Refer to FE section
(“EXHAUST SYSTEM”).
5. Disconnect vehicle speed sensor, transfer neutral position
switch and 4WD switch harness connectors.
6. Remove air breather hose.
7. Remove transfer control lever from transfer outer shift lever.
8. Separate transfer from transmission.
WARNING:
Support transfer while removing it.

ATF007

Installation
● Apply sealant to mating surface of transfer case to transmis-
sion.
● Use genuine anaerobic liquid gasket, Three Bond TB1215,
Loctite Part No. 51813 or equivalent.

SMT495A

● Tighten bolts securing transfer.

Tightening torque
Bolt No. l mm (in)
Nzm (kg-m, ft-lb)

s
1 31 - 41 (3.2 - 4.2, 23 - 30) 45 (1.77)

s
2 31 - 41 (3.2 - 4.2, 23 - 30) 60 (2.36)

SMT496A

TF-8
TRANSFER GEAR CONTROL

GI

MA

EM

LC

EC

FE

CL

MT

AT

TF

PD

FA

RA

BR

ST

RS

BT

HA

EL

IDX

ATF008

TF-9
MAJOR OVERHAUL

Case Components

ATF009

TF-10
MAJOR OVERHAUL

Gear Components GI

MA

EM

LC

EC

FE

CL

MT

AT

TF

PD

FA

RA

BR

ST

RS

BT

HA

EL

IDX

ATF010

TF-11
MAJOR OVERHAUL

Shift Control Components

ATF011

TF-12
 DISASSEMBLY

1. Remove companion flange nut. GI

2. Remove companion flange.

MA

EM

LC
ATF005

3. Remove 4WD switch and vehicle speed sensor. EC

4. Remove rear case.
● Be careful not to damage the mating surface.
FE

CL

MT
SMT270A

5. Remove oil cover and oil gutter. AT

6. Remove snap ring from 2-4 shift rod.
TF

PD

FA
SMT435C

7. Using calipers, measure the difference between front drive RA

sprocket and 2-4 coupling sleeve as outlined under Measuring
method below. If it is outside specifications, check front drive
sprocket, 2-4 coupling sleeve, clutch gear, 2-4 shift fork and BR
2-4 fork rod for abnormalities. Replace faulty part(s) as
required.
Measuring method
ST
a. Move coupling sleeve until it is in contact with sprocket,
then measure dimension A. Move coupling sleeve until it
is in contact with clutch gear, then measure dimension B. RS
Obtain dimensional difference C between two measure-
ments A and B.
C=A−B BT
b. To determine dimension A, measure at 3 or 4 different
points by rotating sprocket and obtain average value of 3
or 4 measurements. HA
Specification C:
Refer to TF-34.
EL

IDX
SMT799CA

TF-13
 DISASSEMBLY

8. Remove bolts securing bearing retainer.

● This step is necessary to remove mainshaft from center
case.

SMT273A

9. Remove bolts securing center case to front case, then separate

center case from front case.

SMT274A

10. Measure low gear end play.

Standard:
0.2 - 0.35 mm (0.0079 - 0.0138 in)
● If end play is not within specification, check low gear and
L & H hub for wear.

SMT342A

11. Disassemble center case assembly.

a. Remove snap ring from mainshaft.

SMT275A

b. Remove low gear with L & H hub.

SMT757A

TF-14
 DISASSEMBLY

c. Remove needle bearing from main shaft. GI

MA

EM

LC
SMT758A

d. Make sure of the direction of the drive chain before removing EC

it. (It must be reinstalled in the same direction.)
FE

CL

MT
SMT788C

e. Remove mainshaft, front drive and drive chain as a set by AT

tapping front end of mainshaft and front drive shaft alternately.
● Be careful not to bend drive chain.
TF

PD

FA
SMT279A

12. Disassemble front case assembly. RA

a. Remove transfer neutral position switch, plugs, check springs
and check balls.
BR

ST

RS
ATF012

b. Remove lock pin from outer shift lever, then remove outer shift
BT
lever.
HA

EL

IDX
ATF013

TF-15
 DISASSEMBLY

c. Remove lock pin from inner shift lever, then drive out cross
shaft and plug together.

SMT282A

d. Remove 2-4 shift rod.

SMT283A

e. Remove L & H shift rod and fork assembly with coupling

sleeve.

SMT284A

f. Remove needle bearing from main gear.

SMT286A

g. Remove bolts securing front case cover, then remove case

cover.

SMT287A

TF-16
 DISASSEMBLY

h. Remove counter gear by tapping lightly. GI

MA

EM

LC
SMT759A

i. Remove main gear by tapping lightly. EC

FE

CL

MT
SMT288A

AT

TF

PD

FA

RA

BR

ST

RS

BT

HA

EL

IDX

TF-17
REPAIR FOR COMPONENT PARTS

Mainshaft
DISASSEMBLY
1. Check front drive sprocket end play.
Standard:
0.2 - 0.35 mm (0.0079 - 0.0138 in)
● If end play is not within specification, check front drive
sprocket and clutch gear for wear.

SMT347A

2. Remove retainer ring, speedometer drive gear and steel ball.

● Be careful not to lose the steel ball.

SMT289A

3. Remove snap ring and spacer.

SMT290A

4. Use a press to remove front drive sprocket with mainshaft rear

bearing and clutch gear together.
5. Remove needle bearing.

SMT291A

6. Remove bearing retainer, then remove snap ring.

SMT292A

TF-18
REPAIR FOR COMPONENT PARTS
Mainshaft (Cont’d)
7. Use a press to remove mainshaft front bearing from mainshaft. GI

MA

EM

LC
SMT293A

INSPECTION EC
Gear and shaft
● Check gears for excessive wear, chips or cracks. FE
● Check shaft for cracks, wear or bending.
● Check coupling sleeve for wear or damage.
CL

MT
SMT348A

Baulk ring AT
● Check baulk ring for cracks or deformation.
TF

PD

FA
SMT349A

● Measure clearance between baulk ring and clutch gear. RA

Baulk ring to clutch gear clearance:
Refer to SDS, TF-34.
BR

ST

RS
SMT350A
BT
Bearing
● Make sure bearings roll freely and are free from noise, cracks,
pitting or wear. HA

EL

IDX
SMT351A

TF-19
REPAIR FOR COMPONENT PARTS
Mainshaft (Cont’d)
ASSEMBLY
1. Press mainshaft front bearing onto mainshaft.
● Pay attention to its direction.

SMT294A

2. Select and install snap ring with proper thickness.

Allowable clearance between snap ring and groove:
0 - 0.15 mm (0 - 0.0059 in)
Available snap ring for mainshaft front bearing:
Refer to SDS, TF-34.
3. For further procedures, refer to ‘‘ASSEMBLY’’, TF-27.

SMT295A

Front Drive Shaft

DISASSEMBLY
● Using a gear puller, remove front drive shaft front and rear
bearings.

SMT437C

INSPECTION
Sprocket and shaft
● Check sprocket for excessive wear, chips or cracks.
● Check shaft for cracks or wear.

Bearing
● Make sure bearings roll freely and are free from noise, cracks,
pitting or wear.

SMT357A

ASSEMBLY
● Press front drive shaft front and rear bearings onto front drive
shaft.

SMT438C

TF-20
REPAIR FOR COMPONENT PARTS

Counter Gear GI
DISASSEMBLY
1. Press out counter gear front bearing. MA
● Remove front sub-gear, dish plate and spacer.
EM

LC
AMT093

2. Press out counter gear rear bearing. EC

● Remove rear sub-gear, dish plate and spacer.
FE

CL

MT
SMT301A

INSPECTION AT
Gear and shaft
● Check gears for excessive wear, chips or cracks. TF
● Check shaft for cracks or wear.

Bearing PD
● Make sure bearings roll freely and are free from noise, cracks,
pitting or wear.
FA
SMT358A

ASSEMBLY RA
1. Install front sub-gear, dish plate and spacer.
2. Press on counter gear front bearing. BR
3. Install rear sub-gear, dish plate and spacer.
4. Press on counter gear rear bearing.
ST

RS
SMT439C
BT
Main Gear
DISASSEMBLY
HA
Main gear bearing
1. Remove snap ring.
EL

IDX
SMT304A

TF-21
REPAIR FOR COMPONENT PARTS
Main Gear (Cont’d)
2. Pull out main gear bearing.

SMT305A

Plug
● Always replace with a new one whenever it has been
removed.

SMT306A

INSPECTION
Gear and shaft
● Check gears for excessive wear, chips or cracks.
● Check shaft for cracks or wear.

Bearing
● Make sure bearings roll freely and are free from noise, cracks,
pitting or wear.

SMT359A

ASSEMBLY
Main gear bearing
1. Press on main gear bearing.

SMT307A

2. Select and install snap ring with proper thickness.

Allowable clearance between snap ring and groove:
0 - 0.15 mm (0 - 0.0059 in)
Available snap ring for main gear bearing:
Refer to SDS, TF-34.

ATF014

TF-22
REPAIR FOR COMPONENT PARTS
Main Gear (Cont’d)
Plug GI
Apply sealant to plug, then install.
● Use genuine anaerobic liquid gasket, Three Bond TB1215,
Loctite Part No. 51813 or equivalent. MA

EM

LC
SMT309A

Front Case EC
SHIFT SHAFT OIL SEAL
FE
Removal
● Use a screwdriver to pry out old seal.
● Be careful not to damage case. CL
● Always replace with a new one whenever it has been removed.

MT
SMT310A

Installation AT
● Install new shift shaft oil seal until flush with case.
● Before installing, apply multi-purpose grease to seal lip. TF

PD

FA
SMT311A

RA
Front Case Cover
COVER OIL SEAL
BR
Removal
● Drive out old seal from inside of front case cover.
● Be careful not to damage front case cover. ST

RS
SMT312A
BT
Installation
● Install new front case cover oil seal until it stops.
● Before installing, apply multi-purpose grease to seal lip. HA

EL

IDX
SMT313A

TF-23
REPAIR FOR COMPONENT PARTS

Bearing Retainer
OIL CATCHER
Removal
● Drive out oil catcher from inside of bearing retainer.
● Be careful not to damage bearing retainer.

SMT314A

Installation
● Install oil catcher until it stops.
● Be careful not to damage or distort oil catcher or bearing
retainer.
● Before installing, apply multi-purpose grease to seal lip.

SMT315A

Center Case
REMOVAL
Center case oil seal
● Remove center case oil seal.

SMT863D

INSTALLATION
Center case oil seal
● Install center case oil seal.

SMT864D

Rear Case
REAR OIL SEAL
Removal
● Pull out rear oil seal.

AMT094

TF-24
REPAIR FOR COMPONENT PARTS
Rear Case (Cont’d)
Installation GI
● Install new rear oil seal until it stops.
● Before installing, apply multi-purpose grease to seal lip.
MA

EM

LC
SMT317A

AIR BREATHER EC
Install as shown in illustration.
● Use genuine thread locker, Three Bond TB1324, Loctite
FE
271 or equivalent.

CL

MT
SMT799A

Shift Control Components AT

INSPECTION
● Check contact surface and sliding surface for wear, scratches, TF
projections or other faulty conditions.
PD

FA
SMT360A

L & H SHIFT ROD & FORK RA

● Assemble as shown in illustration.
BR

ST

RS
* Retaining pin is the same size as the one for 2-4 shift rod.
SMT319A
BT
2-4 SHIFT ROD & FORK
● Assemble as shown in illustration.
HA

EL

IDX
* Retaining pins are the same size.
SMT320A

TF-25
REPAIR FOR COMPONENT PARTS
Shift Control Components (Cont’d)
● Pay special attention to the direction of fork guide collar.

SMT321A

TF-26
 ASSEMBLY

1. Assemble front case. GI

a. Install main gear assembly by tapping lightly.

MA

EM

LC
SMT323A

b. Apply sealant to the mating surface and bolts of front case EC

cover, then attach it to the front case.
● Use genuine anaerobic liquid gasket, Three Bond TB1215,
Loctite Part No. 51813 or equivalent. FE
● These ten bolts should be coated with sealant.
Bolts A:
: 16 - 21 Nzm (1.6 - 2.1 kg-m, 12 - 15 ft-lb) CL
Bolts B:
: 19 - 24 Nzm (1.9 - 2.4 kg-m, 14 - 17 ft-lb) MT
SMT325A

c. Apply ATF to needle bearing and install it into main gear. AT

TF

PD

FA
SMT326A

d. Install counter gear assembly by tapping lightly. RA

BR

ST

RS
SMT327A

e. Install cross shaft and inner shift lever.

BT
● When replacing cross shaft, outer shift lever or outer shift
lever lock pin, replace them as a set. HA

EL

IDX
SMT798A

TF-27
 ASSEMBLY

f. Apply sealant to plug, then install it into front case.

● Use genuine anaerobic liquid gasket, Three Bond TB1215,
Loctite Part No. 51813 or equivalent.

SMT330A

g. Insert interlock plunger into front case.

SMT331A

h. Install L & H shift rod and fork assembly with coupling sleeve.

SMT332A

i. Install 2-4 shift rod.

ATF015

j. Install transfer neutral position switch, check balls, check

springs and plugs.
● Apply sealant to switch and plugs.
● Use genuine anaerobic liquid gasket, Three Bond TB1215,
Loctite Part No. 51813 or equivalent.

ATF012

TF-28
 ASSEMBLY

2. Select counter gear rear bearing shim. GI

a. Seat counter gear assembly.

MA

EM

LC
SMT590A

b. Place J34291-1 (bridge), J34291-2 (legs) and J34291-5 (gaug- EC

ing cylinder) on machined surface of center case, allowing
gauging cylinder to rest on top outer portion of counter gear
rear bearing. Lock gauging cylinder in place. FE

CL

MT
SMT591A

c. Insert J34291-20 (gauging plunger) into J34291-5 (gauging AT

cylinder).
TF

PD

FA
SMT592A

d. Place bridge, legs, gauging cylinder and gauging plunger onto RA

machined surface of front case assembly, allowing gauging
plunger to drop until it contacts counter gear rear bearing mat-
ing surface. BR

ST

RS

BT

HA

EL

IDX
SMT593A

TF-29
 ASSEMBLY

e. Lock gauging plunger in place and use feeler gauge to mea-

sure end play between gauging cylinder and gauging plunger.
f. Use measured distance to select correct counter gear rear
bearing shim.
Allowable counter gear end play:
0 - 0.2 mm (0 - 0.008 in)
Available counter gear rear bearing shim:
Refer to SDS, TF-34.

SMT594A

3. Place suitable shim with grease on counter gear rear bearing.

4. Apply ATF to each part in front case.

SMT336A

5. Assemble center case assembly.

a. Install mainshaft on center case by tapping lightly.
● Apply ATF to mainshaft front bearing.

SMT406A

b. Install bearing retainer.

: 16 - 21 Nzm (1.6 - 21 kg-m, 12 - 15 ft-lb)

SMT407A

c. Put drive chain onto the front drive sprocket and front drive
shaft, and then put them in center case.
● Be sure to install drive chain in same direction as
removed.

SMT408A

TF-30
 ASSEMBLY

GI

MA

EM

LC
SMT409A

d. Install front drive shaft by tapping lightly. EC

● Make sure shafts are aligned in the case.
FE

CL

MT
SMT410A

e. Apply ATF to needle bearings and install them into front drive AT
sprocket.
● These needle bearings will be installed more easily if front
drive sprocket is rotated while installing them. TF

PD

FA
SMT411A

f. Install 2-4 coupling sleeve with 2-4 shift fork. RA

● Pay attention to the direction of the coupling sleeve.
BR

ST

RS
SMT412A

g. Install shifting inserts and spread spring.

BT
● Pay attention to the direction of shifting inserts.
HA

EL

IDX
SMT353A

TF-31
 ASSEMBLY

h. Install baulk ring, then install clutch gear and mainshaft rear
bearing.
● Place wooden block under mainshaft in order to protect
mainshaft front bearing.

SMT413A

i. Install spacer.
j. Select and install snap ring with proper thickness.
Allowable clearance between snap ring and groove:
0 - 0.15 mm (0 - 0.0059 in)
Available snap ring for mainshaft rear bearing:
Refer to SDS, TF-34.

SMT414A

k. Install steel ball, speedometer drive gear and retainer ring.

● Steel ball is the smallest check ball for this unit.

SMT415A

l. Install low gear and bearing onto mainshaft.

● Apply ATF to needle bearing.

SMT340A

m. Install L & H hub and snap ring onto mainshaft.

● Pay attention to the direction of L & H hub.

SMT760A

TF-32
 ASSEMBLY

n. Measure low gear end play. GI

● Standard: 0.2 - 0.35 mm (0.0079 - 0.0138 in)

MA

EM

LC
SMT342A

6. Apply sealant to mating surface of center case, then attach to EC

front case and tighten bolts.
● Use genuine anaerobic liquid gasket, Three Bond TB1215,
Loctite Part No. 51813 or equivalent. FE

CL

MT
SMT343A

7. Install snap ring to 2-4 shift rod. AT

TF

PD

FA
SMT272A

8. Install oil gutter and oil cover. RA

9. Apply ATF to each part in center case.
BR

ST

RS
SMT344A

10. Apply sealant to mating surface of rear case, then attach it to

BT
center case and tighten bolts.
● Use genuine anaerobic liquid gasket, Three Bond TB1215,
Loctite Part No. 51813 or equivalent. HA
11. Install 4WD switch and vehicle speed sensor.
● Apply sealant to switch threads. EL
● Use genuine anaerobic liquid gasket, Three Bond TB1215,
Loctite Part No. 51813 or equivalent.
IDX
SMT497C

TF-33
 SERVICE DATA AND SPECIFICATIONS (SDS)

General Specifications
Transfer model TX10A
High 1.000
Gear ratio
Low 2.020
Main gear 29
Low gear 37

Counter High 38
Number of teeth
gear Low 24
Front drive sprocket 41
Front drive shaft 41
Fluid capacity l (US qt, Imp qt) 2.2 (2-3/8, 2)

Inspection and Adjustment

CLEARANCE BETWEEN FRONT DRIVE AVAILABLE SNAP RING
SPROCKET AND 2-4 COUPLING SLEEVE
Unit: mm (in)
Mainshaft front bearing Unit: mm (in)
Allowable clearance ‘‘C’’ 0.2 - 0.54 (0.008 - 0.0213)
Allowable clearance 0 - 0.15 (0 - 0.0059)
Thickness Part number
3.1 (0.122) 33138-73P10
GEAR END PLAY
Unit: mm (in) 3.19 (0.126) 33138-73P11

Front drive sprocket 0.2 - 0.35 (0.0079 - 0.0138) 3.28 (0.129) 33138-73P12

Low gear 0.2 - 0.35 (0.0079 - 0.0138)

Counter gear 0 - 0.2 (0 - 0.008)

Main gear bearing Unit: mm (in)

Allowable clearance 0 - 0.15 (0 - 0.0059)

CLEARANCE BETWEEN BAULK RING AND
CLUTCH GEAR Thickness Part number
Unit: mm (in) 2.60 (0.102) 33114-73P00
Standard Wear limit 2.69 (0.106) 33114-73P01
1.0 - 1.5 (0.039 - 0.059) 0.5 (0.020) 2.78 (0.109) 33114-73P02

AVAILABLE SHIM
Mainshaft rear bearing Unit: mm (in)

Counter gear rear bearing Unit: mm (in) Allowable clearance 0 - 0.15 (0 - 0.0059)

Allowable clearance 0 - 0.2 (0 - 0.008) Thickness Part number

Thickness Part number 1.8 (0.071) 33138-73P20

0.1 (0.004) 33112-C6900 1.89 (0.074) 33138-73P21

0.2 (0.008) 33112-C6901 1.98 (0.078) 33138-73P22

0.3 (0.012) 33112-C6902 2.07 (0.081) 33138-73P23

0.4 (0.016) 33112-C6903 2.16 (0.085) 33138-73P24

0.5 (0.020) 33112-33G00

0.6 (0.024) 33112-33G01

TF-34