TOYOTA LAND CRUISER (Light-Duty) REPAIR MANUAL FOR CHASSIS & BODY INTRODUCTION HIM CLUTCH MANUAL TRANSMISSION TRANSFER PROPELLER SHAFT [ia FRONT AXLE AND SUSPENSION HZ REAR AXLE AND SUSPENSION [GY BRAKE SYSTEM HE STEERING Mi BODY ELECTRICAL SYSTEM EEE BODY EE WINCH AIR CONDITIONING SYSTEM EEXe SERVICE SPECIFICATIONS [EW STANDARD BOLT TORQUE SPECIFICATIONS HE = SST AND SSM ELECTRICAL WIRING DIAGRAMS ©1892 TOYOTA MOTOR CORPORATION Aa ghee sonved. Te it be who without the written permission of T Motor Corporation.INTRODUCTION HOW TO USE THIS MANUAL IDENTIFICATION INFORMATION GENERAL REPAIR INSTRUCTIONS . VEHICLE LIFT AND SUPPORT LOCATION ABBREVIATIONS USED IN THIS MANUALINTRODUCTION — How To Use This Manual HOW TO USE THIS MANUAL To assist in finding your way through the manual, the section title and major heading are given at the top of every page. An INDEX is provided on the first page of each section to guide you to the item to be repaired. At the beginning of each section, PRECAUTIONS are gi pertain to all repair operations contained in that section. Read these precautions before starting any repair task. TROUBLESHOOTING tables are included for each system to help you diagnose the system problem and find the cause. The repair for each possible cause is referenced in the remedy col- umn to quickly lead you to the solution. in that REPAIR PROCEDURES Most repair operations begin with an overview illustration which identifies the components and shows how the parts fit together. Example (ae i gee (Feb, + Specified torque @ + Non-reusable part Outer Bearing Adjusting Nut Lock Nut Axle Hub with DiseINTRODUCTION — How To Use This Manual IN3 Mustration: what to do and where ‘The procedures are presented in a step-by-step format: © The illustration shows what to do and where to do it. © The task heading tells what to do. © The detailed text tells how to perform the task and gives other information, such as specifications and warnings. Example: _/ Task heading: what to do # CONNECT PROPELLER SHAFT FLANGE TO COMPANION FLANGE (2) Align the marks on the flanges and connect the flanges with four bolts and nuts. (b) Torque four bolts end nuts. Detail text: how to do it Torque: 600 — 750 ko-om (44 — 54 ft-lb, 59 — 73 N-m) “Specification This format enables the experienced technician to have a FAST TRACK. He can read the task headings and refer to the de- tailed text only when he needs it. Important specifications and warnings always stand out in bold type, REFERENCES References have been kept to a minimum. However, when they are required you are given the page to go to. SPECIFICATIONS Specifications are presented in bold type throuyhout the tex: ‘the applicable step. You never have to leave the procedure to look up your specs. All specifications are also found in Appen- dix A, specifications for quick reference. WARNINGS, CAUTIONS, NOTES: © WARNINGS are presented in bold type, and indicate there is. a possibility of injury to you or other people. © CAUTIONS are also presented in bold type, and indicate the Possibility of damage to the components being repairer © NOTES are separated from the text but do not appear in bold. They provide additional information to help you etti- ciently perform the repair.IN-4 INTRODUCTION — Identification Information, General Repair Instructions IDENTIFICATION INFORMATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped on the cowl panel of the engine compartment. ENGINE SERIAL NUMBER The engine serial number is stamped on the cylinder block, es shown, GENERAL REPAIR INSTRUCTIONS Use fender, seat and floor covers to keep the vehicle clean and prevent damage. 2 During disassembly, keep parts in order to facilitate re- assembly. 3. Observe the following: (a) Before performing electrical work, disconnect the cable from the battery termin (b) If it is necessary to disconnect the battery for inspec- tion or repair, always disconnect the cable from the negative (—) terminal which is grounded to the vehi- cle body. {c) To prevent damage to the battery terminal post, loosen the terminal nut and raise the cable straight up without twisting or prying it. {d) Clean the battery terminal posts and cable termi with a shop rag. Do not scrape them with a such,INTRODUCTION General Repair Instructions INS (e) Install the cable terminal to the battery post with the nut loose and tighten the nut after installation. Do not use a hammer, or such, to tap the terminal ‘onto the post. (f) Be sure the cover for the positive (+) terminal is pro- perly in place. 4. Check hose and wiring connections to make sure that they are secure and correct. 5. Nor-reusable Parts: 10. WW. (a) Always replace cotter pins, gaskets, O-rings and oil seals, etc. with new ones. (b) Non-reusable parts are indicated in the component illustrations by the “@” symbol. Precoated Parts: Precoated parts are the bolts, nuts, etc. which are coated with a seal lock adhesive at the factory. (a) If a precoated part is retightened, loosened or caused ‘to move in any way, it must be recoated with the specified adhesive, {b) Recoating of Precoated Parts (1) Clean off the old adhesive from the bolt, nut or installation part threads, (2) Dry with compressed air. (3) Apply the specified seal lock adhesive to the bolt or nut threads. (c)_ Precoated parts are indicated in the component illust- rations by the "Se" symbol. When necessary, use a sealer on gaskets to prevent leaks. Carefully observe all bolt torque specifications. Always use a torque wrench. Use of special service tools (SST) and special service materials (SSM) may be required, depending on the nature of the repair. Be sure to use SST and SSM where specified and follow the proper work procedure. A list of SST and ‘SSM can be found at the back of this manual. When replacing fuses, be sure the new fuse is the correct amperage rating. DO NOT exceed the fuse amp rating or use one of a lower rating. Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations (See page IN-6). {a) If the vehicle is to be jacked up only at the front or rear end, be sure to block the wheels to ensure safety. (b) After the vehicle is jacked up, be sure to support it on stands. It is extremely dangerous to do any work on a vehicle raised on a jack alone, even for a small job that can be finished quickly.ING INTRODUCTION — Vehicle Litt and Support Locations VEHICLE LIFT AND SUPPORT LOCATIONS JACK POSITION ee Front ........-. Under the frontdifferential BOM crete ne Under the rear differential Safety stand ...-... | | SUPPORT POSITION |INTRODUCTION — Abbrevit ions Used In This Manual IN-7 ABBREVIATIONS USED IN THIS MANUAL Alc A/T, ATM Air Conditioner Automatic Circuit Breaker Except Front Ignition Inch Lefthand Left-hand Drive Load Sensing Proportioning Valve M um Multipurpose Manual Transmission Option Power Steering Power Take-off Right-hand Right-hand Drive Rear Special Service Materials Tools Temperature Vacuum Switching Valve With WithoutCLUTCH Page TROUBLESHOOTING . cL.2 CHECK AND ADJUSTMENT OF CLUTCH PEDAL . cL3. BLEEDING OF CLUTCH SYSTEM cL3 CLUTCH MASTER CYLINDER .. cL 4 CLUTCH RELEASE CYLINDER . cle CLUTCH UNIT cL8cL2 CLUTCH — Troubleshooting TROUBLESHOOTING Problem Possible cause Remedy Page Hord to shift or Clutch pedal freeplay excessive Adjust pedal freeplay Ls ‘will not shire Air in clutch lines Bleed clutch system cs Clutch release cylinder feutty Repair release cylinder cs Clutch master cylinder faulty Repair master cylinder cL4 Clutch disc out of true, runout is excessive or | Inspect eluteh disc as Iining broken Splines on input shaft or clutch disc Repeir as necessary ce dirty or burred ‘Clutch pressure plate faulty Replace pressure plate ce Transmission jumps Clutch pilot bearing worn Replace pilot bearing cs out of gear ‘Clutch slips Clutch pedal freepley insufficient : ‘Adjust pedal freeplay as Clutch disc lining oly or worn out Inspect cluteh dise as Pressure plate faulty Replace pressure plato cas Release fork binding Inspect release fork Clutch grabs/chatters | Clutch disc olly or worn out Inspect clutch dise cLe Pressure plate fulty Replace pressure plate Le (Clutch diaphragm spring bent Align clutch diaphregm CLs Engine mounts loose Repair as necessary Clutch pedal spongy Ai in cluteh lines Bleed clutch system CLs (Clutch release cylinder faulty Repair release cylinder ce Clutch mester oylinder faulty Repair master cylinder cL4 Clutch noisy Loose part inside housing Repair as necessary 5 Release bearing worn or dirty Replace release bearing cs Pilot bearing worn Replace pilot bearing as Release fork or linkage Repair as necessaryCLUTCH — Check and Adjustment of Clutch Pedal, Bleeding of Clutch System cL3 Push Rod Play Adjust Point Ya_ Pedal Height Adjust Point Push Rod CHECK AND ADJUSTMENT OF CLUTCH PEDAL Ty; CHECK THAT PEDAL HEIGHT AND PUSH ROD PLAY ARE CORRECT Pedal height: 186 mm (7.32 in.) Push rod play at pedal top: 1—5 mm (0.04 — 0.20 in.) If incorrect, adjust the pedal height and push rod play. IF NECESSARY, ADJUST PEDAL HEIGHT AND PUSH ROD PLAY (a) Loosen the lock nut and turn the stopper bolt until the height is correct. Tighten the lock nut. (bd) Loosen the lock nut and turn the push rod until the push rod play is correct. Tighten the lock nut. CHECK PEDAL FREEPLAY IS CORRECT Push in on the pedal until the beginning of clutch resist- ance is felt. Pedal freeplay: LJ §—15 mm (0.20 —0.59 in.) RJ 13 —23 mm (0.51 — 0.91 in.) IF NECESSARY, ADJUST PEDAL FREEPLAY (2) Loosen the lock nut and turn the push rod until the freeplay is correct (b) Tighten the lock nut. {c) After adjusting the pedal freeplay, check the pedal height. BLEEDING OF CLUTCH SYSTEM NOTE: If any work is done on the clutch system or if air is suspected in the clutch lines, bleed the system of air. CAUTION: DO NOT let brake fluid remain on a painted surface. Wash it off immediately. FILL CLUTCH RESERVOIR WITH BRAKE FLUID Check the reservoir frequently and add fluid if necessary. CONNECT VINYL TUBE TO BLEEDER PLUG Insert the other end of the tube in a half-full container of brake fluid. BLEED CLUTCH LINE (a) Slowly pump the clutch pedal several times. (b) While pressing on the pedal, loosen the bleeder plug until the fluid starts to run out. Then close the bleeder plug. (c) Repeat this procedure until there are no more air bubbles in the fluid,cL4 CLUTCH — Clutch Master Cylinder CLUTCH MASTER CYLINDER COMPONENTS Reservoir Tank S < | Piston gp 0% Master Cylinder Push Rod Clovis ENT] + Specitied worque 8° @ = Non-reusable part exons REMOVAL OF MASTER CYLINDER 1 DRAW OUT FLUID WITH SYRINGE 2. DISCONNECT CLUTCH LINE UNION Using SST, disconnect the union. SST 09751-36011 3, DISCONNECT CLEVIS FROM CLUTCH PEDAL Remove the clip and clevis pin, disconnect the clevis from the clutch pedal. 4. REMOVE MASTER CYLINDER Remove the two mounting nuts and pull off the master cylinder.CLUTCH Clutch Master Cylinder DISASSEMBLY OF MASTER CYLINDER 1, REMOVE PUSH ROD AND SNAP RING (a) Pull back the boot and remove the snap ring with a screwdriver. (b) Pull off the push rod and washer. 2, REMOVE RESERVOIR TANK 3. REMOVE PISTON Using compressed air, remove the piston from the cylinder. TY Ady aman sesteGhes! | INSPECTION OF MASTER CYLINDER ana INSPECT MASTER CYLINDER ea Inspect the disassembled parts for wear, rust or damage. Aus ASSEMBLY OF MASTER CYLINDER (See page CL-4) Se 1. COAT PARTS WITH LITHIUM SOAP BASE @ ewan GLYCOL GREASE 2, INSTALL PISTON INTO CYLINDER 3. INSTALL PUSH ROD ASSEMBLY WITH SNAP RING 4. INSTALL RESERVOIR TANK Torque: 250 kg-em (18 ft-lb, 25 N-m) INSTALLATION OF MASTER CYLINDER 1. INSTALL MASTER CYLINDER 2. CONNECT CLEVIS AND CLUTCH PEDAL Connect the clevis and clutch pedal with clevis pin and clip. 3. CONNECT CLUTCH LINE UNION Using SST, connect the union. SST 09751-36011 4. ADJUST CLUTCH PEDAL AND BLEED SYSTEM (See page CL-3)CLé CLUTCH — Clutch Release Cylinder CLUTCH RELEASE CYLINDER COMPONENTS Push Rod oo CY Cara) « Sct toraue = REMOVAL OF RELEASE CYLINDER 1, REMOVE FLEXIBLE HOSE {a) Using SST, disconnect the union. SST 09751-36011 {b) Remove the clip from flexible hose. ‘ssT (c) Loosen and remove the flexible hose from the release cylinder. 2. REMOVE RELEASE CYLINDER @ DISASSEMBLY OF RELEASE CYLINDER 1, PULL OFF PUSH ROD 2. REMOVE BOOT 3. REMOVE PISTON Using compressed air, remove the piston from the cylinder. we INSPECTION OF RELEASE CYLINDER INSPECT RELEASE CYLINDER —— — Se Inspect the disassembled parts for wear, rust or damage.CLUTCH — Clutch Release Cylinder cCL.7 Lithium Soap Base Glycol Grease ASSEMBLY OF RELEASE CYLINDER } (See page CL-6) 1, COAT PISTON WITH LITHIUM SOAP BASE GLYCOL GREASE, AS SHOWN 2. INSTALL PISTON 3. INSTALL BOOT AND INSERT PUSH ROD INSTALLATION OF RELEASE CYLINDER (See page CL-6) 1. INSTALL RELEASE CYLINDER WITH TWO BOLTS Torque: 120 kg-cm (9 ft-tb, 12 N-m) 2. INSTALL FLEXIBLE HOSE {a) Install the flexible hose to the release cylinder. (b) Using SST, connect the union. SST 09751-36011 (c) Install the clip, 3. BLEED CLUTCH SYSTEM (See page CL-3)cL8 CLUTCH — Clutch Unit CLUTCH UNIT COMPONENTS Clutch Dise Clutch Cover Clutch Release Bearing | Cluteh Release Bearing Hub Clip laa Release Fork gf iP Ha) + seciied tora ans REMOVAL OF CLUTCH UNIT 4. REMOVE TRANSMISSION (See page MT-3) NOTE: Do not drain the transmission oil. [Karem Te 2, REMOVE CLUTCH COVER AND DISC (a) Put alignment marks on the clutch cover and flywheel. (b) Loosen the set bolts one turn at a time until spring tension is released. (c) Remove the set bolts and pull off the clutch cover and disc.CLUTCH — Clutch ui 3. REMOVE BEARING, HUB AND FORK FROM TRANSMISSION (a) Remove the retaining clip and pull off the bearing and hub. {b) Remove the fork and boot. INSPECTION OF CLUTCH PARTS 1. INSPECT CLUTCH DISC FOR WEAR OR DAMAGE Using calipers, measure the rivet head depth. Minimum rivet depth: 0.3 mm (0.012 in.) If @ problem is found, replace the clutch disc. 2. INSPECT CLUTCH DISC RUNOUT Using a dial indicator, check the disc runout. Maximum runout: 0.8 mm (0.031 in.) Hf runout is excessive, replace the disc. 3, INSPECT FLYWHEEL RUNOUT Using a dial indicator, check the flywheel runout. Maximum runout: 0.2 mm (0.008 in.) If runout is excessive, replace the flywheel. 4, INSPECT PILOT BEARING Turn the bearing by hand while applying force in the rota- tion direction. If the bearing sticks or has much resistance, replace the pilot bearing. NOTE: The bearing is permanently lubricated and re- quires no cleaning or lubrication.CL-10 CLUTCH — Clutch Unit IF NECESSARY, REPLACE PILOT BEARING (a) Using SST, remove the pilot bearing. SST 09303-35011 (b) Using SST, instal! the pilot bearing. SST 09304-30012 NOTE: After assembling the pilot bearing to the hub, in. ‘sure that it rotates smoothly. INSPECT DIAPHRAGM SPRING FOR WEAR Using calipers, measure the diaphragm spring for depth and width of wear. Maximum: Depth 0.6 mm (0.024 in.) Width 5.0 mm (0.197 in.) IF NECESSARY, REPLACE PRESSURE PLATE (a) _ Drill out the rivet heads, (b) Disconnect the retracting springs from the pressure plate. ()_ Using a punch, drive out the rivets. {d) Apply molybdenum disulphide lithium base grease {NLGI No. 2) to the contact surface of the pressure plate bolts and nuts. Torque the nuts. (e) Connect @ new pressure plate and the retracting springs with the special pressure plate bolts and nuts. Torque the nuts. Torque: 195 kg-cm (14 ft-lb, 19 Nem) (f) Using @ punch, stake the nuts.CLUTCH — Clutch U =) TTT 6 cot 8. INSPECT RELEASE BEARING ‘Turn the bearing by hand while applying force in the axial direction. If bearing sticks or has much resistance, replace the release bearing. NOTE: The bearing is permanently lubricated and re- quires no cleaning or lubrication, 9. IF NECESSARY, REPLACE RELEASE BEARING (a) Using a press and SST, press the release bearing from the hub, SST 09315-00010 (b) Using a press and SST, press a new release bearing into the hub, SST 09315-00021 (c) After installing the bearing, check that there is no drag on the bearing when it is turned under pressure, INSTALLATION OF CLUTCH UNIT (See page CL-8) 1. INSTALL DISC ON FLYWHEEL Using SST, instal] the dise on the flywheel, ‘SST 09301-20020 2, INSTALL CLUTCH COVER {a} Align the marks on the clutch cover and flywheel. (b) Tighten the bolts evenly. Make several passes around the cover until it is snug. Torque the bolts. Torque: 195 kg-cm (14 ft-lb, 19 N-m)eL-12 CLUTCH — Glutch Unit 3. CHECK DIAPHRAGM SPRING TIP ALIGNMENT Using a dial indicator and measuring point, check the diaphragm spring tip alignment. Maximum non-alignment: 0.5 mm (0.020 in.) If alignment is excessive, adjust as follows. IF NECESSARY, ADJUST SPRINGS Using SST, bend the springs to correct alignment. ‘SST 09333-00012 APPLY MOLYBDENUM DISULPHIDE LITHIUM BASE GREASE (NLGI NO. 2) OR MP GREASE (a) Apply molybdenum disulphide lithium base grease to the following parts: @ Release fork and hub contact point ‘@ Release fork and push rod contact point © Release fork pivot point Clutch disc spline © Release bearing hub insi groove (b) Apply molybdenum disulphide lithium base grease to release bearing. INSTALL BOOT, FORK, HUS AND BEARING ON TRANSMISSION INSTALL TRANSMISSION (See page MT-35) pitti nei iia nnd! aanMT-1 MANUAL TRANSMISSION Page TROUBLESHOOTING ........0....ceceeeeeee MT-2 REMOVAL OF TRANSMISSION .. MT-3 G40 AND G52F TRANSMISSIONS MT-5 Components ...... MT-5 Disassembly of Transmission MT-7 Inspection of Transmission Components MT-16 Assembly of Transmission MT-21 INSTALLATION OF TRANSMISSION .......... MT-35MANUAL TRANSMISSION — Troubleshooting MT-2 TROUBLESHOOTING Problem Possible cause | Remedy Page | Hard to shift or witt | Splines on input shaft dirty or burred | Repair as necessary MTS nae sie Transmission faulty Disassemble and inspect MT-3 a Dicassemble and inspect =| MTS Transmission jumps out of gear Transmission faulty transmissionMANUAL TRANSMISSION — Removal of Transmission MT-3 ee REMOVAL OF TRANSMISSION 1, DISCONNECT BATTERY CABLE FROM NEGATIVE KK TERMINAL i, 2. DRAIN OUT COOLANT (RJ) 3. DISCONNECT UPPER HOSE AND ENGINE REAR : HEATER HOSE (RJ) 4, REMOVE TRANSMISSION SHIFT LEVER (a) Remove the shift lever boot. (b) Cover the shift lever cap with a cloth. (c) Then, pressing down on the shift lever cap, rotate it counterclockwise to remove. {d) Remove the shift lever. 6. RAISE VEHICLE AND DRAIN OUT TRANSMISSION AND TRANSFER GEAR OIL 6. REMOVE TRANSMISSION UNDERCOVER 7. REMOVE FRONT AND REAR PROPELLER SHAFTS (See page PR-3) 8. DISCONNECT BOND CABLE FROM BODY REMOVE SPEEDOMETER CABLE 10, REMOVE DIAPHRAGM CYLINDER VACUUM HOSE (ELECTRICAL SHIFT TYPE)MT-4 MANUAL TRANSMISSION — Removel of Transmissi 1 12, 13, 4. 15. 16. 7. 19, 20. n REMOVE 4WD AND BACK-UP LIGHT SWITCH CONNECTOR REMOVE L4 SWITCH CONNECTOR (ELECTRICAL SHIFT TYPE) REMOVE TRANSFER SHIFT LEVER REMOVE CLUTCH RELEASE CYLINDER REMOVE STARTER {a) Disconnect the cable and connector. (b) Remove the starter. REMOVE EXHAUST PIPE CLAMP AND BRACKET DISCONNECT ENGINE REAR SUPPORT MEMBER FROM BODY (a) Support the engine rear supportmember with the jack. (b) Remove the bolts from both sides of the support member. LOWER TRANSMISSION REMOVE TRANSMISSION WITH TRANSFER (a) Disconnect the transmission mounting bolts from the engine. (b) Remove the transmission with the transfer. REMOVE ENGINE REAR SUPPORT MEMBER Remove the engine rear support member from the trans mission.MANUAL TRANSMISSION — G40 and G52F Transmissions MTS G40 AND G52F TRANSMISSIONS COMPONENTS Teer Retin kup Light Switch 380127, 37) & Straight Screw Plug —Q prorat, Output Shaft — Looking Belt Spring ht Screw Plugp—7—F gn ° Counter Gear < [eee a} G ae A ~s oe iG! —+e Straight Screw Plug [700 Dat ‘Shift Lever. Shift Lever Shaft y erie] Housing Sara Foren osriet Pin Shift Fork Shaft No. 2 (4-Speed) Reverse B = Shift Head Shift Fork Shaft No. 5 4 WS Shitt Fork No. 3 ean - Sm (Tb, Nem)] ; Specified torque : Nor-reusable part 4: Precoated part Restrict Pin [38020, 27) a Roverse Shift Arm 0 mate Bs o ie a ee © Shift Fork Shaft No. 3 Remaesntt aimee | [Be0re7. a7] Front Bearing Retainer Clutch Housing 380 27, 37) [3750377 Pos e Reverse Idler ‘Gear Shaft Idler Gear Input Shaft Shift Fork No, 2 200.178, 20) rod Shift Fork Shaft No. 1 rere] ‘Shift Fork Shaft No, 4MT-6 MANUAL TRANSMISSION G40 and G52F Transmissions COMPONENTS (Cont'd) ‘Sleeve Rear Bearing Retainer ‘Synchronizer Ring [r00 167, 170] Se Gear Spline Piece No. 5 il Separator (4-Speed) ‘Counter Rear Bearing Sl A) Counter Gear ont ae ©, bide. | Needle E Bearing ‘Snap Ring Rear Bearing Needle Roller Bearing Inner Race Synchronizer Ring ce Hub Sieeve No. 1 Synchronizer Ring 2nd Gear ee vp ~ | Needle Roller Bearing t Ml }) A 65 i ' 1 ! jgey 3rd Gear Needle Ratlr Bearing Synchronizer Ring L0 wale DED O@a kg-em (ft-lb, N @ = Non-teus ecitied torque = i Hub Sleeve No. 2MANUAL TRANSMISSION — G40 and G52F Transmissions MT-7 —_.__ | DISASSEMBLY OF TRANSMISSION (See pages MT-5, 6) REMOVE CLUTCH HOUSING 1 2. REMOVE BACK-UP LIGHT SWITCH, SHIFT LEVER RETAINER AND RESTRICT PINS 3. REMOVE TRANSFER (See page TF-12) 4, REMOVE STRAIGHT SCREW PLUG, SPRING AND BALL (2) Using @ torx socket wrench, remove the screw plug from the transfer adapter. {b) Using a magnetic finger, remove the spring and ball 5. REMOVE TRANSFER ADAPTER (a) Remove the shift lever housing set bolt and lock washer, {b) Remove the shift lever shaft and housing.MANUAL TRANSMISSION — G40 and G52F Transmissions 2 (c) Remove the eight bolts. > (d) Using a plastic hammer, remove the transfer adapter NOTE: Leave the gasket attached to the intermediats plate. i REMOVE FRONT BEARING RETAINER AND TWO BEARING SNAP RINGS SEPARATE INTERMEDIATE PLATE FROM TRANS- MISSION CASE {a} Using a plastic hammer, carefully tap off the trans mission case. {b) Remove the transmission case from the intermediate plate MOUNT INTERMEDIATE PLATE IN VISE (a) Use two clutch housing bolts, plate washers and suit- able nuts as shown. CAUTION: _ Install the plate washers in reverse of normal. Increase or decrease plate washers so that the bolt tip and front tip surface of the nut are aligned. (b) Mount the intermediate plate in a vise. REMOVE STRAIGHT SCREW PLUGS, LOCKING BALLS AND SPRINGS (2) Using a torx socket wrench, remove the plugs. 4Speed: Three plugs S-Speed: Four plugsMANUAL TRANSMISSION — G40 arid G52F Transmissions MT-9 (b) Using a magnetic finger, remove the springs and balls, 10. REMOVE BOLTS AND SLOTTED SPRING PINS (2) Remove the bolts from the shift fork No. 1 and No. 2. (b) Using a pin punch and hammer, drive out the pins 4Speed: Two pins Speed: Three pins 11. REMOVE E-RINGS 4Speed: Four E-rings 5Speed: Two E-rings 12. REMOVE SHIFT FORK SHAFT NO.4 AND SHIFT FORK NO. 3 (5-Speed) (a) Pull out the shift fork shaft No. 4 from the interme- diate plate, CAUTION: The locking balls and interlock pin will fall from the holes so be sure to catch them by hand. If they do not come out, remove them with a magnetic finger. (b) Remove the shift fork shaft No. 4 and the shift fork No. 3,MANUAL TRANSMISSION — G40 and G52F Transmissions owes 13. 14, 15. 16. 17. REMOVE REVERSE SHIFT HEAD AND SHIFT FORK SHAFT NO.5 Pull out the shift fork shaft No. 5 from the intermediate plate, and remove it with the reverse shift head. REMOVE SHIFT FORK SHAFT NO.3 Pull out the shift fork shaft No. 3 from the intermediate plate. CAUTION: The interlock pins will fall from the hole, so be ready to catch them by hand. If they do not come out, remove them with a magnetic finger. REMOVE SHIFT FORK SHAFT NO. 1 Pull out the shift fork shaft No. 1 from the intermediate plate. CAUTION: The interlock pin will fall from the hole so be sure to catch it by hand. If it does not come out, remove it with a magnetic finger. REMOVE SHIFT FORK SHAFT NO. 2, SHIFT FORK NO. 2 AND SHIFT FORK NO. 1 Pull out shift fork shaft No. 2 and remove shift fork No. 2 and No. 1. REMOVE REVERSE IDLER GEAR AND SHAFT (a) Remove the reverse idler gear shaft stopper. (b) Remove the reverse idler gear and shaft.MANUAL TRANSMISSION — G40 and G52F Transmissions MT-11 18. REMOVE REVERSE SHIFT ARM FROM REVERSE SHIFT ARM BRACKET MEASURE COUNTER FIFTH GEAR THRUST CLEARANCE (5-Speed) Using a feeler gauge, measure the counter 5th gear thrust clearance. Standard clearance: 0.10 — 0.30 mm (0.0039 — 0.0118 in.) Maximum clearance 0.30 mm (0.0118 in.) 20-1 REMOVE GEAR SPLINE PIECE NO. 5, SYNCHRO- NIZER RING, NEEDLE ROLLER BEARINGS AND COUNTER FIFTH GEAR WITH HUB SLEEVE NO. 3 (5-Speed) (a) Engage the gear double meshing. (b) Using a hammer and chisel, loosen the staked part of the nut. (c) Remove the lock nut. (d)_ Disengage the gear double meshing. (e) Using SST, remove the gear spline piece No. 5, syn- chronizer ring, hub sleeve No. 5, needle roller bearing and counter 5th gear. SST 09213-27010MT-12 MANUAL TRANSMISSION — G40 and G52F Transmissions 20.2REMOVE OIL SEPARATOR (4Speed) (a) Engage the gear double meshing. {b) Using a hammer and chisel, loosen the staked part of the nut, {c) Remove the nut. {d) Remove the oil separator. (e) Disengage the gear double meshing. 21 REMOVE SPACER AND BALL (5-Speed) (a) Remove the spacer. (b) Using a magnetic finger, remove the ball 22, REMOVE REVERSE SHIFT ARM BRACKET Remove the two bolts and the reverse shift arm bracket. 23, REMOVE REAR BEARING RETAINER Using a torx socket wrench, remove the four bolts,MANUAL TRANSMISSION — G40 and G52F Transmissions MT-13 a 24, 25. 26. 27. 28. REMOVE BEARING SNAP RING Using snap ring pliers, remove the snap ring. REMOVE OUTPUT SHAFT, COUNTER GEAR AND. INPUT SHAFT AS A UNIT FROM INTERMEDIATE PLATE (a) Remove the output shaft, counter gear and input shaft, as 4 unit, from the intermediate plate by pull- ing on the counter gear and tapping on the inter- mediate plate with a plastic hammer. (b) Remove the input shaft with the 14-needle roller bearings from the output shaft, REMOVE COUNTER REAR BEARING FROM INTERMEDIATE PLATE Using SST, remove the counter rear bearing, SST 09608-12010 REMOVE SLEEVE FROM OUTPUT SHAFT Using SST, remove the sleeve from the output shaft. ‘SST 09950-20016 MEASURE EACH GEAR THRUST CLEARANCE Measure the thrust clearance of each gear. Standard clearance: 0.10 — 0.25 mm {0.0039 — 0.0098 in.) Maximum clearance: 0.25 mm (0.0098 in.)MT-14 MANUAL TRANSMISSION — G40 and G52F Transmissions 29.1 REMOVE FIFTH GEAR, REAR BEARING, FIRST GEAR, INNER RACE AND NEEDLE ROLLER BEARING (5-Speed) (2) Using two screwdrivers and a hammer, tap out the snap ring. {b) Using a press, remove the Sth gear, rear bearing, 1st gear and inner race, {c)_ Remove the needle roller bearing. 29.2 REMOVE REAR BEARING, FIRST GEAR, INNER RACE AND NEEDLE ROLLER BEARING (4Speed) (2) Using two screwdrivers and a hammer, tap out the snap ring. 5 ~ ] {b) Using a press, remove the rear bearing, 1st gear and | | Wate \ (c) Remove the needle roller bearing. 30. REMOVE SYNCHRONIZER RING ~ 31, REMOVE LOCKING BALL Using a magnetic finger, remove the locking b: LE.MANUAL TRANSMISSION — G40 and G52F Transmissions MT15 32, REMOVE HUB SLEEVE NO.1 ASSEMBLY AND SECOND GEAR ASSEMBLY {a) Using a press, remove the hub sleeve No. 1, synchro- nizer ring and 2nd gear. (b) Remove the needle roller bearing. 93. REMOVE HUB SLEEVE NO.2 ASSEMBLY AND THIRD GEAR ASSEMBLY (2) Using snap ring pliers, remove the snap ring {b) Using press, remove the hub sleeve No. 2, synchro- nizer ring and 3rd gear. (c)_ Remove the needle roller bearing.MT-16 MANUAL TRANSMISSION — G40 and G52F Transmissions INSPECTION OF TRANSMISSION COMPONENTS | 1. INSPECT OUTPUT SHAFT AND INNER RACE OD, (2) Using calipers, meaure the output shaft flange thick- FA Se ness. Ve | Minimum thickness: 4.80 mm (0.1890 in.) (b) Using calipers, measure the inner race flange thickness. Minimum thickness: 3.99 mm (0.171 in.) (c)_ Using a micrometer, measure the outer diameter of the output sheft journal. jimum diameter: 2nd gear 37.984 mm (1.4954 in.) 3rd gear 34,984 mm (1.3773 in.) (d) Using @ micrometer, measure the outer diameter of the inner race. jinimum diameter: 38.985 mm (1.5348 in.) (©) Using a dial indicator, check the shaft runout. Maximum runout: 0,05 mm (0.0020 in.)MANUAL TRANSMISSION wes z. G40 and G52F Transmissions eet CHECK OIL CLEARANCE OF FIRST GES* Using a dial indicator, measure the oil clears the gear and inner race with the needle rolle * stalled, Standard clearance: 0,009 — 0.032 mm (0.0004 — 0.0013 in.) Maximum clearance: 0.032 mm (0.0013 in.) CHECK OIL CLEARANCE OF SECOND, TH'*> AND COUNTER FIFTH GEARS Using a dial indicator, measure the oil clearanc the gear and shaft with the needle roller bearing Standard clearance: 2nd and 3rd gears 0.009 — 0.033 mm {0.0004 — 0.0013 in.) Counter Sth gear 0.009 — 0.032 mm (0.0004 — 0.0013 in.) Maximum clearance: 2nd and 3rd gears 0.033 mm (0,0013 in.) Counter 5th gear 0.032 mm (0,0013 in.) INSPECT SYNCHRONIZER RINGS (2) Turn the ring and push it in to check the 8 48i"g action (b) Measure the clearance between the synchror' ing back and the gear spline end, Standard clearance: 1.0 - 2.0mm (0.039 — 0,079 in.) Minimum clearance: 0.8 mm (0.031 in.) MEASURE CLEARANCE OF SHIFT FORKS AMI) HUB SLEEVES Using a feeler gauge, measure the clearance betvin! (Ne hub sleeve and shift fork. Maximum clearance: 1.0 mm (0,039 in.)MT-18 MANUAL TRANSMISSION — G40 and G52F Transmissions i Si~SO IF NECESSARY, REPLACE INPUT SHAFT BEARING {a) Using snap ring pliers, remove the snap ring. (b) Using a press, remove the bearing. (c) Using a press and SST, install a new bearing. SST 09506-35010 (d) Select a snap ring that will allow minimum axial play and install it on the shaft. 2.05 — 2.10 210-215 2.15 -2.20 220-225 2.26 - 2.20 2.30 - 2.95 7. IF NECESSARY, REPLACE FRONT BEARING RETAINER OIL SEAL (2) Using a screwdriver, pry out the oil seal.MANUAL TRANSMISSION — G40 and G52F Transmissions MT-19 (b) Using SST, press in the oil seal. SST 09223-50010 Oil seal depth: 12.2 — 13.2 mm (0.480 — 0.520 in.) Transmission case installation surface 8. IF NECESSARY, REPLACE COUNTER GEAR FRONT BEARING {a) Using snap ring pliers, remove the snap ring. {b) Using SST, press out the bearing. SST 09950-00020 {c) Replace the side race. () Using a socket wrench, press in the bearing, side race and inner race. {e) Select a snap ring that will allow minimum axial play ‘and install it on the shaft. Thickness min (in, 2.05 = 2.10 {0.0807 — 0.08: 210-215 (0.0827 — 0.084 215-220 (0.0846 ~ 0.0866 2.20-2.25 (0.0866 — 0.0886) 2.25-230 (0.0886 ~ 0.0906) 230-235 (0.0906 ~ 0.0925) IF NECESSARY, REPLACE REVERSE RESTRICT PIN {a) Using a torx socket wrench, remove the screw plug.MT-20 MANUAL TRANSMISSION — G40 and G52F Transmissions ————} (e) | (c) (d) fe) — (f ‘Using @ pin punch and hammer, drive out the slott spring pin. Pull off the reverse restrict pin. Install the reverse restrict pin. Using @ pin punch and hammer, drive in the slott spring pin, Using a torx socket wrench, install and torque t screw plug. Torque: 190 kg-cm (14 ft-lb, 19 Nem)MANUAL TRANSMISSION — G40 and G52F Transmissions ASSEMBLY OF TRANSMISSION (See pages MT-5, 6) Te 1. INSERT CLUTCH HUBS NO.1 AND NO. 2 INTO HUB SLEEVE elias {a) Install the clutch hub and shifting keys to the hub sleeve. (b) Install the shifting key springs under the shiftingkeys. CAUTION: Install the key springs positioned so that ‘their end gaps are not in line. 2. INSTALL THIRD GEAR AND HUB SLEEVE NO.2 ON OUTPUT SHAFT {a) Apply gear oil to the shaft and needle roller bearing, (b) Place the synchronizer on the gear and align the ring slots with the shifting keys. (c) Install the needle roller bearing in the 3rd gear. {d) Using a press, install the 3rd gear “and hub sleeve No. 2. 3. INSTALL SNAP RING (a) Select a snap ring that will allow minimum axial play. (b) Using snap ring pliers, install the snap ring. Mark C-1 | 1.75—1.80mm (0.0689 — 0.0709 in.) D | 1.80 1.85 mm (0.0709 — 0.0728 in.) 0-1 | 1.85-1.90 mm (0.0728 ~ 0.0748 in.) E | 1.90—1.95mm (0.0748 ~ 0.0768 in.) E41 | 1,952.00 mm (0.0768 ~ 0.0787 in.) F | 2,002.05 mm (0.0787 ~ 0.0807 in.) F_| 208-210 mm (0.0807 — 0.0827 in.)MT-22 MANUAL TRANSMISSION — G40 and G52F Transmissions —S - 4, MEASURE THIRD GEAR THRUST CLEARANCE Using a feeler gauge, measure the 3rd gear thrust cleara) \ Standard clearance: 0.10 — 0.25 mm [ ~~ (0.0039 — 0.0098 in.) & Maximum clearance: 0.25 mm (0.0098 in.) 5. INSTALL SECOND GEAR AND HUB SLEEVE No, (2) Apply gear oil to the shaft and needle roller bearing x (b) Place the synchronizer ring on the gear and align t . rring slots with the shifting keys. (c) Install the needle roller bearing in the 2nd gear. (d) Using a press, install the 2nd gear and hub sleev No. 1 6. INSTALL LOCKING BALL AND FIRST GEAR ASSEMBLY {a) Install the locking ball in the shaft. {b) Apply gear oil to the needle roller bearing. {c) Assemble the 1st gear, synchronizer ring, needle rollet bearing and bearing inner race. i chronizer ring slots aligned with the shifting keys. (d) install the assembly on the output shaft with the 37@@ Turn the inner race to align it with the locking ball. 1MANUAL TRANSMISSION — G40 and G5: 7 10 Transmissions MT-23 INSTALL OUTPUT SHAFT REAR BEARING Using SST and a press, install the bearing on the output shaft with the outer race snap ring groove toward the rear. NOTE: Hold the 1st gear inner race to prevent it from falling, ‘SST 09506-25010 MEASURE FIRST AND SECOND GEAR THRUST CLEARANCE Using a feeler gauge, measure the 1st and 2nd gear thrust clearance. ‘Standard clearance: 0.10 ~ 0.25 mm (0.0039 — 0.0098 in.) Maximum clearance 0.25 mm (0.0098 in.) INSTALL FIFTH GEAR (5-Speed) Using SST and a press, install the 5th gear SST 09506-35010 INSTALL SNAP RING (a) Select a snap ring that wit = w min axial play {b) Using a screwdriver and hammer install the snap ring. Wark Wickes 2.73 ras 2.79 2.94 (0.1098 — 16-3.201012% ——260)] [298 2.90 (0.1122 0,114; 21-3.26 101% 1283) € [291 2.96 (0.1148 -0.116t 27 - 3.32 (0.128 307] 2.97 3.02 (0.1160-0.1186MT-24 MANUAL TRANSMISSION — G40 and G52F Transmissions 11, INSTALL SLEEVE TO OUTPUT SHAFT Using @ plastic hammer, tap the sleeve onto the output shaft. 12, INSTALL OUTPUT SHAFT TO INTERMEDIATE PLATE Install the output shaft into the intermediate plate by pull- ing on the output shaft and tapping on the intermediate plat 13. INSTALL INPUT SHAFT (2) Apply MP grease to the 14-needle roller bearing and install it into the input shaft. (b) Install the input shaft to the output shaft with the synchronizer ring slots aligned with the shifting keys. 14, INSTALL COUNTER GEAR Install the counter gear into the intermediate plate while holding the counter geer, and install the counter rear bear- ing with SST. SST 09316-60010MANUAL TRANSMISSION — G40 and G52F Transmissions MT-25 15. 16. 7. 18. 19, INSTALL BEARING SNAP RING Using snap ring pliers, install the snap ring. NOTE: Be sure the snap ring is flush with the intermedi: ate plate surface. INSTALL REAR BEARING RETAINER Using a torx socket wrench, install and torque the screws. Torque: 185 kg-cm (13 ft-lb, 18 N-m) INSTALL REVERSE SHIFT ARM BRACKET Install the reverse shift arm bracket and torque the bolts. Torque: 185 kg-cm (13 ft-lb, 18 N-m) INSTALL BALL AND SPACER (5-Speed) INSERT COUNTER FIFTH GEAR INTO HUB SLEEVE NO. 3 (5-Speod) {a) Install the shifting keys and hub sleeve No. 3 onto the counter 5th gear. (b) Install the shifting key springs under the shifting keys. CAUTION: Install the key springs positioned so that their end gaps are not in line.MT-26 MANUAL TRANSMISSION — G40 and G52F Transmissions 21. 22. INSTALL COUNTER FIFTH GEAR WITH HUB SLEEVE NO.3 ASSEMBLY AND NEEDLE ROLLER BEARINGS (5-Speed) (2) Apply gear oil to the needle roller bearings. (b) Install the counter 5th gear with hub sleeve No. 3 and needle roller bearings. INSTALL SYNCHRONIZER RING AND GEAR SPLINE PIECE NO.6 (5-Speed) (a) Install the synchronizer ring on the gear spline piece No. 5. {b) Using SST, drive in the gear spline piece No. § with the synchronizer ring slots sligned with the shifting keys. SST 09316-60010 NOTE: When installing the gear spline piece No. 5, sup- port the counter gear in front with a 35 Ib hammer or equivalent. INSTALL OIL SEPARATOR (4-Speed) INSTALL LOCK NUT (a) Engage the gear double meshing. (b) Install and torque the lock nut. Torque: 1,200 kg-cm (87 ft-lb, 118 N.m) {c) Stake the lock nut.MANUAL TRANSMISSION — G40 and G52F Transmissions MT-27 27. (d) _Disengage the gear double meshing. MEASURE COUNTER FIFTH GEAR THRUST CLEARANCE (5-Spoed) Using a feeler gauge, measure the counter 5th gear thrust clearance, ‘Standard clearance: 0.10 — 0.30 mm (0.0039 — 0.0118 in.) Maximum clearance: 0.30 mm (0.0118 in.) INSTALL REVERSE SHIFT ARM TO REVERSE SHIFT ARM BRACKET Install the reverse shift arm to the pivot of the reverse shift arm bracket. INSTALL REVERSE IDLER GEAR AND SHAFT (a) Install the reverse idler gear on the shaft. (b) Align the reverse shift arm shoe to the reverse idler gear groove and insert the reverse idler gear shaft to the intermediate plate. (c) Install the reverse idler gear shaft stopper and torque the bolt. Torque: 175 kg-cm (13 ft-lb, 17 Nm) INSTALL SHIFT FORK SHAFT NO. 2, SHIFT FORK NO. 1 AND NO. 2 Place shift forks No. 1 and No. 2 into the groove of hub sleeves No. 1 and No, 2 and install fork shaft No. 2 to shift forks No. 1 and No. 2 through the intermediate plate.28. 29. 30. 31. MANUAL TRANSMISSION — G40 and G52F Transmissions INSTALL INTERLOCK PIN (2) Apply MP grease to the interlock pins, (b) Using a magnetic finger and screwdriver, install the interlock pin into the intermediate pla INSTALL SHIFT FORK SHAFT NO.1 (a) Install the interlock pin into the shaft hole. {b) Install the fork shaft No. 1 to the shift fork No. 1 through the intermediate plate. INSTALL INTERLOCK PIN Using @ magnetic finger and screwdriver, install the inter- lock pin into the intermediate plate. INSTALL SHIFT FORK SHAFT NO. 3 (2) Install the interlock pin into the shaft hole,MANUAL TRANSMISSION — G40 and G52F Tr 32. 33. {b) Install the fork shaft No. 3 to the reverse shift arm through the intermediate plate. INSTALL SHIFT FORK SHAFT NO.5 AND. REVERSE SHIFT HEAD (2) Install the reverse shift head to the fork shaft No. 5. (b) Insert fork shaft No. 5 to the intermediate plate and put in the reverse shift head to shift fork shaft No. 3. INSTALL SHIFT FORK SHAFT NO. 4, SHIFT FORK NO. 3 AND TWO LOCKING BALLS (5-Speed) (a) Using a magnetic finger and screwdriver, install the locking ball into the reverse shift head hole. (b) Shift hub sleeve No, 3 to the 5th speed position. (c) Place shift fork No. 3 into the groove of hub sleeve No. 3 and install fork shaft No. 4 to shift fork No. 3 and reverse shift arm.MT.30 MANUAL TRANSMISSION — G40 and G52F Transmissions {d) Using a magnetic finger and screwdriver, install the locking ball into the intermediate plate and insert fork shaft No. 4 to the intermediate plate. 34, CHECK INTERLOCK (a) Shift the fork shaft No. 1 to the Ist speed position (b) Fork shafts No, 2, No. 3, No. 4 and No. 5 should not move. 35. INSTALL SLOTTED SPRING PINS (2) Install the bolts to the shift fork No. 1 and No. 2. Torque: 200 kg-cm (14 ft-lb, 20 N-m) {b) Using @ pin punch and hammer, drive in the slotted spring pins into the reverse shift arm, reverse shift head and shift fork No. 3 (5-Speed). 36. INSTALL E-RINGS 4-Speed: Four E-rings 5-Speed: Two E-ringsMANUAL TRANSMISSION G40 and G52F Transmissions MT-31 37. 39. a. INSTALL LOCKING BALLS, SPRINGS AND SCREW PLUGS (a) Apply liquid sealer to the plugs. {b) Install the locking balls, springs and screw plugs and ‘Torque the screw plugs with a torx socket wrench, Torque: 190 kg-em (14 ft-lb, 19 N-m) NOTE: (5:Speed) Install the short spring into the bot- tom of the intermediate plate. DISMOUNT INTERMEDIATE PLATE FROM VISE {a) Dismount the intermediate plate from the vise. (b) Remove the bolts, nuts, plate washers and gasket. INSTALL TRANSMISSION CASE WITH NEW GASKET TO INTERMEDIATE PLATE Align each bearing outer race, each fork shaft end and reverse idler gear shaft end with the case installation holes, and install the case. If necessary, tap on the case with a plastic hammer. . INSTALL TWO BEARING SNAP RINGS INSTALL FRONT BEARING RETAINER WITH NEW GASKET (2) Install the bearing retainer with a new gasket. (b) Apply liquid sealer to the bolts. {c) Install and torque the bolts. Torque: 170 kg-cm (12 fb, 17 N-m)MT-32 MANUAL TRANSMISSION — G40 and G52F Transmissions = 42. INSTALL TRANSFER ADAPTER, NEW GASKET, | i, | SHIFT LEVER SHAFT AND SHIFT LEVER < HOUSING {a} Install a new gasket to the intermediate plate, | (b) Install and torque the transfer adapter with the eight bolts. Torque: 380 kg-cm (27 ft-lb, 37 N-m) (c) Insert the shift lever housing to the transfer adapter and connect the fork shafts. (d) Insert the shift lever shaft to the transfer adapter and shift lever housing. (e) Install and torque the shift lever housing bolt. Torque: 390 kg-cm (28 ft-lb, 38 Nm) (f) Stake the lock washer.MANUAL TRANSMISSION G40 and G52F Transmissi ions MT-33 43. INSTALL LOCKING BALL, SPRING AND SCREW PLUG (2) Apply liquid sealer to the plug. (b) Install the locking ball and spring. {c) Install and torque the plug. Torque: 190 kg-em (14 ft-lb, 19 N-m) AFTER INSTALLING TRANSFER ADAPTER CHECK FOLLOWING ITEMS (a) Check to see that the input and output shafts rotate smoothly. (b) Check to see that shifting can be made smoothly to all positions, INSTALL RESTRICT PINS {a) Install the black pin on the reverse gear/5th gear side. (b) Install another pin and torque the pins. Torque: 280 kg-em (20 ft-lb, 27 N-m)MT-34 MANUAL TRANSMISSION — G40 and G52F Transmissions 46. 47. 49. INSTALL CLUTCH HOUSING (a) Install the clutch housing. (b) Install and torque the bolts. Torque: 380 kg-cm (27 ft-lb, 37 Nem) INSTALL SHIFT LEVER RETAINER WITH NEW GASKET Torque: 185 kg-cm (13 ft-lb, 18 Nm) INSTALL BACK-UP LIGHT SWITCH Torque: 380 kg-em (27 ftib, 37 N-m) INSTALL_TRANSFER (See page TF-25)MANUAL TRANSMISSION — Installation of Transmission MT-35 INSTALLATION OF TRANSMISSION 1 INSTALL ENGINE REAR SUPPORTMEMBER Install the engine rear supportmember to the transmission, Torque the bolt. Torque: 260 kg-cm (19 ft-lb, 25 Nm) INSTALL TRANSMISSION WITH TRANSFER Align the input shaft spline with the clutch disc, and install the transmission to the engine. 10 mm 380 kg-cm (27 ft-lb, 37 N-m) 12 mm 730 kg-cm (53 ft-lb, 72 N-m) CONNECT ENGINE REAR SUPPORTMEMBER TO BODY Torque the eight bolts. Torque: 400 kg-cm (29 ft-lb, 39 N.m) INSTALL EXHAUST PIPE CLAMP AND BRACKET INSTALL STARTER (a) Install the starter with the two bolts, Torque: 730 kg-cm (53 ft-lb, 72 N-m) (b) Connect the cable and connector. INSTALL CLUTCH RELEASE CYLINDER Torque: 120 kg-em (9 ft-lb, 12 Nem) INSTALL TRANSFER SHIFT LEVER TO TRANSFER INSTALL 4WD AND BACK-UP LIGHT SWITCH CONNECTOR INSTALL L4 SWITCH CONNECTOR (ELECTRICAL SHIFT TYPE)MT-36 MANUAL TRANSMISSION — Installation of Transmission [ - 10. INSTALL SPEEDOMETER CABLE | 11. CONNECT BOND CABLE TO BODY 12 INSTALL DIAPHRAGM CYLINDER VACUUM HOSE | (ELECTRICAL SHIFT TYPE) . INSTALL FRONT AND REAR PROPELLER SHAFTS (See page PR:7) INSTALL TRANSMISSION UNDERCOVER INSTALL TRANSMISSION SHIFT LEVER (a) Cover the shift lever cap with a cloth. {b) Then, install by rotating clockwise while applying downward pressure. {c) Install the shift lever boot. . INSTALL UPPER HOSE AND ENGINE REAR HEATER HOSE (RJ) . FILL WITH COOLANT (RJ) |. CONNECT BATTERY CABLE TO NEGATIVE TERMINAL . FILL TRANSMISSION AND TRANSFER WITH OIL | | Oil grade: wt APIGL-4,5 SAE 75W-90 Capacity: Transmission G40 2.8 liters (3.0 US qts, 2.5 Imp. qts) G52F 2.6 liters (2.7 US qts, 2.3 Imp. qts) Transfer 2.1 liters (2.2 US qts, 1.8 Imp, gts) 20. PERFORM ROAD TEST Check for abnormal noise and smooth operation.TRA TRANSFER TROUBLESHOOTING . TRANSFER . On-Vehicle Replacement of Front and Rear Output Shaft Oil Seal Removal of Transfer Diaphragm Cylinder Components... . Disassembly of Diaphragm Cylinder Inspection of Diaphragm Cylinder Components Assembly of Diaphragm Cylinder . Transfer Components . . Disassembly of Transfer . Inspection of Transfer Components . Assembly of Transfer Installation of Transfer ELECTRICAL SHIFT TYPE .....TF2 TRANSFER — Troubleshooting TROUBLESHOOTING Problem Possible cause Romady Pago Hard to shitt or will Splines on input shaft dirty oF Repair es necessary “TFS not shift burred Transter faulty Disossemble and inspect transfer TF.3 Transfer jumps out of | Transfer faulty Disassemble and inspect tranefer TFS gearTRANSFER — Transfer TF TRANSFER | Companion Flange 7300164, 127, Companion Flange {Specified torque © =: Non-reussble part en] ON-VEHICLE REPLACEMENT OF FRONT AND REAR OUTPUT SHAFT OIL SEAL 1. DRAIN GEAR OIL FROM TRANSFER 2. REMOVE TRANSFER UNDER COVER 3. REMOVE FRONT AND REAR PROPELLER SHAFT (See page PR-3) 4, REMOVE COMPANION FLANGE (a) Using @ hammer and chisel, loosen the staked part of the nut. (b) Using SST to hold the companion flange, remove the ‘companion flange lock nut. SST 09330-00021 {c) Remove the companion flange.TRANSFER — Transfer FRONT REAR FRONT REAR FRONT REAR 5. REMOVE OIL SEAL Using SST, remove the output shaft oil seal, SST 09308-10010 INSTALL OIL SEAL {a) Using SST, drive in a new oil seal. SST 09316-60010 {b) Apply MP grease to the oil seal lip. INSTALL COMPANION FLANGE (e) Install the companion flange. (b) Using SST to hold the companion flange, install the companion flange lock nut. SST 09330-00021 Torque: 1,300 kg-em (94 ft-lb, 127 N-m) (c)_ Stake the companion flange lock nut. INSTALL FRONT AND REAR PROPELLER SHAFTS (See page PR-7) Torque: 750 kg-cm (64 ft-1b, 74 N-m) INSTALL TRANSFER UNDERCOVER FILL TRANSFER WITH OIL Oilgrade: API GL-4,5 SAE 90 Capacity: 2.1 liters (2.2 US qts, 1.8 Imp. ats) REMOVAL OF TRANSFER (See page MT-3)TRANSFER Transfer TFS DIAPHRAGM CYLINDER COMPONENTS Diaphragm Cylinder = Body Cover e—____ ssi. <> rate (Qa $011 —_ > = __——¢o.in Suction Tube (a75 27, 37) Digphraam Cylinder Cover T=} — ey ‘Diaphragm Push Rod @Gasker @ Gasket ‘Shoe Shift Link Lever ~ Steaight Pit [Diaphragm cyiinger Boay (aera) DISASSEMBLY OF DIAPHRAGM CYLINDER 1, REMOVE DIAPHRAGM CYLINDER ASSEMBLY (2) Remove the diaphragm cylinder assembly from the diaphragm cylinder body. (b) Remove the gasket. 2. REMOVE SHIFT LINK LEVER AND STRAIGHT PINTF6 TRANSFER — Transfer 3. REMOVE SHOE FROM SHIFT LINK LEVER Using @ pin punch and hammer, remove the two shoes from the shift link lever, REMOVE DIAPHRAGM CYLINDER BODY (a) Remove the diaphragm cylinder body from the trans- fer case, {b) Remove the gasket. INSPECT DIAPHRAGM CYLINDER ASSEMBLY (2) With at least 400 mmHg (15.75 in.Hg, 53.3 kPa) of vacuum in the diaphragm, confirm that the shaft moves. Standard stroke: 22 mm (0.87 in.) {b) Confirm again on the diaphragm side, {c) With at least 400 mmHg of vacuum in the diaphragm, confirm the gauge needle is stable, REMOVE SUCTION TUBE (2) Remove the suction tube from the diaphragm cylin- der body cover. (b) Remove the gasket. REMOVE DIAPHRAGM CYLINDER BODY COVERTRANSFER ransfer Tl 8. REMOVE FOLLOWING PARTS FROM DIAPHRAGM PUSH ROD © Two washers © Two plates © Diaphragm © O-ring INSPECTION OF DIAPHRAGM CYLINDER COMPONENTS IF NECESSARY, REPLACE OIL SEAL (a) Using a screwdriver, remove the oil seal, {b) Using @ socket wrench, drive in a new oil seal, {cl Apply MP grease to the oil seal lip. 7TES TRANSFER Transfer Cutout Portion a | ( ASSEMBLY OF DIAPHRAGM CYLINDER ‘is INSTALL FOLLOWING PARTS TO DIAPHRAGM PUSH ROD ‘© Two washers © Two plates ‘© Diaphragm © O-ring TORQUE DIAPHRAGM PUSH ROD NUT Torque: 375 kg-em (27 ft-lb, 37 N-m) INSTALL DIAPHRAGM PUSH ROD INTO DIAPHRAGM CYLINDER COVER INSTALL DIAPHRAGM CYLINDER BODY COVER Install the diaphragm cylinder body cover to the diaph: ragm cylinder cover. Torque the bolts. Torque: 75 kg-cm (65 inwib, 7.4 N-m) INSTALL SUCTION TUBE Torque: 375 kg-cm (27 ft-lb, 37 N-m) INSTALL DIAPHRAGM CYLINDER BODY Install the diaphragm cylinder body with a new gasket to the transfer case. Torque the bolts. Torque: 185 kg-cm (13 ft-lb, 18 N-m)TRANSFER — Transfer TF9 7 INSTALL SHOE TO SHIFT LINK LEVER Using a press, install two shoes to shift link lever. INSTALL SHIFT LINK LEVER AND STRAIGHT PIN (a) Apply MP grease to shoe and straight pin. (b) Install the shift link lever and straight pin. INSTALL DIAPHRAGM CYLINDER ASSEMBLY Install the diaphragm cylinder assembly with a new gasket to the diaphragm cylinder body. Torque the bolts, Torque: 185 kg-cm (13 ft-lb, 18 N-m)TRANSFER — Transfer TRANSFER COMPONENTS TF-10 Transfer Input Shaft Front Case Oil Seal “Sonn gs ~~) — o\ re yoni oor Gear Shaft $ ose Front Companion Flange Front Output Shaft - Retainer «egy @) gol YU) Bearing Retainer Oil Seal lee 72 | 6 Rear Output Shaft © _— [mma High and Low Outer Lover kgem (fib, Nm)] : Specified torque @ = Non-reusable part 1 _: Procauted part 77 vain 650147, 64) {14 mm 400 (26 39) rae — Dust Boot © ‘~~ Spring (a a} oe Ball Spring ——4 © Ot Seat Locking Bet—= High and Low Inner Lever High and Low Shift Fork Shaft < @ High end Low Shift Fork Front Drive Shift Fork Shatt 185.7, 15) Case Cover No. 2 © Gasket Power Take Off Cover y (i702. + [eos] | Rear Companion Flango| Front Drive Shift ForkTRANSFER — Transfer COMPONENTS (Cont'd) Transfer Input Gear Power Take-off Drive Gear Spacer Bearing [1.300198 127] ‘Snap Ring O-Ring Oil Receiver Thrust Washer: Idler Gear Shaft Lock Plate Transfer Input Shatt Bearing Snap Ring Clutch Sleeve Snap Ring Front Output Shatt Bearing Front Output Shaft High Gear Rear Output Shatt Front Bearing Rear Output Shaft Low Gear Rear 3 Beari eaialaee Output Shaft Rear Bearing Adjusting Shim tem ( © Nonseurabie part Nem] © Specitied torqueTRANSFER — Tran: DISASSEMBLY OF TRANSFER (See pages TF-10, 11) fle REMOVE DIAPHRAGM CYLINDER (ELECTRICAL SHIFT TYPE) (See page TF-5) REMOVE TRANSFER FRONT DRIVE SHIFT LEVER (MECHANICAL SHIFT TYPE) {a) Remove the transfer front drive shift lever. {b) Remove the dust boot. REMOVE 4WD INDICATOR SWITCH Using SST, remove the 4WD indicator switch. SST 09817-16011 4, REMOVE L4 POSITION SWITCH (ELECTRICAL SHIFT TYPE) REMOVE PLUGS, SPRINGS AND LOCKING BALLS [Mechanical Shitt Type] Remove the plugs and, using a magnetic finger, remove the springs and locking balls. [Electrical Shift Type] Remove the plug an spring and locking ball. using a magnetic finger, remove the REMOVE SPEEDOMETER DRIVEN GEARTRANSFER ~ Transfer TF13 7. 10. REMOVE TRANSMISSION OUTPUT SHAFT LOCK NUT (a) Remove the transfer case cover No. 2 and gasket. (b) Using a hammer and chisel, loosen the staked part of the nut. (c)_ Using SST to hold the rear companion flange, remove the transmission output shaft lock nut. ‘SST 09330-00021 REMOVE FRONT AND REAR COMPANION FLANGE (2) Using a hammer and chisel, loosen the staked part of the nut. {b) Using SST to hold the companion flange, remove the companion flange lock nut. SST 09330-00021 {c) Remove the companion flange, REMOVE POWER TAKE-OFF COVER Remove the six bolts, and remove the power take-off cover. MEASURE IDLER GEAR THRUST CLEARANCE Using a feeler gauge, measure the clearance between the idler gear and thrust washer. Standard clearance: 0.275 — 0.625 mm (0.0110 — 0.0246 in.) Maximum clearance: 0.625 mm (0.0246 in.)TR-14 TRANSFER — Transfer 11. REMOVE REAR OUTPUT SHAFT REAR BEARING RETAINER {a) Remove the six bolts, and remove the rear output shaft rear bearing retainer. {b) Remove the speedometer drive gear and spacer. 12, REMOVE IDLER GEAR SHAFT LOCK PLATE 13. REMOVE TRANSFER REAR CASE (a) Remove the bolts. (b) Using a plastic hammer, remove the transfer rear case, 14, REMOVE REAR OUTPUT SHAFT ASSEMBLY WITH SHIFT FORK AND SHIFT FORK SHAFTTRANSFER — Transfer TRAS 15. REMOVE SHIFT FORK SHAFT {a) Using a pin punch and hammer, drive out the slotted spring pin. {b) Remove the shift fork shaft from the shift fork. Use a set of soft jaws in the vise to protect the 3. REMOVE TRANSFER INPUT SHAFT REAR BEARING, POWER TAKE-OFF DRIVE GEAR AND SPACER (2) Using SST, remove the transfer input shaft rear bearing, ‘SST 09950-20016 {b) Remove the power take-off drive gear and spacer. . REMOVE TRANSFER INPUT GEAR Using SST, remove the transfer input gear SST 09950-20016 REMOVE IDLER GEAR, BEARINGS, SPACER, THRUST WASHERS AND IDLER GEAR SHAFT (2) Remove the O-ring. (b) Remove the idler gear, thrust washers, bearing and spacer. {c) Remove the i . REMOVE REAR OUTPUT SHAFT FRONT BEARING RETAINER Using SST, remove the output shaft front bearing retainer. ‘SST 09308-10010TF-16 TRANSFER — Transfer 20. 21. 22. REMOVE CLUTCH SLEEVE Remove the clutch sleeve with the shift fork and shift fork shaft. REMOVE SHIFT FORK SHAFT [Mechanical Shift Type] {a) Using a pin punch and hammer, drive out the slotted spring pin. (b) Remove the shift fork from the shift fork shaft, [Electrical Shift Type} (a) Remove the retainer, spring and shift fork from the shift fork shaft. (b) Using snap ring pliers, remove the snap ring. REMOVE TRANSFER FRONT CASE (2) Remove the five bolts, (b) Using a plastic hammer, remove the transfer front case,TRANSFER — Transfer TF-17 23. REMOVE TRANSFER INPUT SHAFT FROM TRANSFER ADAPTER 24. REMOVE FRONT OUTPUT SHAFT Using a press, remove the front output shaft. 25. REMOVE TRANSFER HIGH AND LOW SHIFT OUTER AND INNER LEVER 26. MEASURE LOW AND HIGH GEAR THRUST CLEARANCE (a) Using a feeler gauge, measure the high gear thrust clearance. Standard clearance: 0.10 — 0.25 mm (0.0039 — 0.0098 in.) Maximum clearance: 0.25 mm (0.0098 in.) {b) Using a feeler gauge, measure the low gear thrust clearance, ‘Standard clearance: 0.10 — 0.25 mm (0.0039 — 0.0098 in.) Maximum clearance: 0.25 mm (0.0098 in.)TF-18 TRANSFER — Transfer 27. 28. REMOVE HIGH GEAR FROM REAR OUTPUT SHAFT (2) Using snap ring pliers, remove the snap ring, {b) Using a press and socket wrench, remove the follow. ing parts, © Clutch hub © Output shaft front bearing © High gear REMOVE LOW GEAR FROM REAR OUTPUT SHAFT Using a press, remove the following parts, ‘© Output shaft rear bearing © Low gear Clutch sleeveTRANSFER _ Transfer TF19 INSPECTION OF TRANSFER COMPONENTS. 1 INSPECT REAR OUTPUT SHAFT (a) Check the rear output shaft for wear or damage. (b) Using @ micrometer, measure the outer diameter of the rear output shaft journal surface. Minimum outer diameter: Part A 40.009 mm (1.5752 in.) B 40.009 mm (1.5752 in.) {c) Using a dial indicator, check the shaft runout. Maximum runout: 0.03 mm (0.0012 in.) CHECK OIL CLEARANCE OF LOW AND HIGH GEAR (a) Using a dial indicator, measure the oil clearance be- tween the high gear and rear output shaft. ‘Standard clearance: 0.035 — 0.081 mm {0.0014 — 0.0032 in.) Maximum clearance: 0.081 mm (0.0032 in.) (b) Using a dial indicator, measure the oil clearance be- ‘tween the low gear and rear output shaft, ‘Standard clearance: 0,035 — 0.081 mm (0.0014 — 0.0032 in.) Maximum clearance: 0.081 mm (0.0032 in.) MEASURE CLEARANCE OF SHIFT FORKS AND HUB SLEEVES Using a feeler gauge, measure the clearance between the hub sleeves and shift fork, Maximum clearance: 1.0 mm (0.039 in.)TF-20 TRANSFER — Transfer —sst 4 IF NECESSARY REPLACE REAR OUTPUT SHAFT PILOT BEARING {a) Using SST, remove the rear output shaft pilot bearing, SST 09319-60020 NOTE: The bearing will break. {b) Using SST, press in a new pilot bearing. SST 09608-20011 (c) Apply MP grease to the pilot bearing. IF NECESSARY, REPLACE REAR OUTPUT SHAFT FRONT BEARING OUTER RACE (a) Using SST, remove the rear output shaft front bearing outer race, SST 09514-35011 bearing retainer. ‘SST 09316-60010 IF NECESSARY, REPLACE REAR OUTPUT SHAFT REAR BEARING OUTER RACE {a) Using SST, remove the rear output shaft rear bearing outer race and shim SST 09514-35011TRANSFER — Transfer TF21 (b) Install the thinnest shim into the rear bearing retaine (c) Using SST, press in a new rear outer race to the rear bearing retainer. SST 09316-60010 7 IF NECESSARY, REPLACE FRONT OUTPUT SHAFT OIL SEAL (a) Using a screwdriver, remove the oil seal. {b) Using SST, drive in a new oil seal. SST 09316-60010 (c) Apply MP grease to the oil seal lip 8. IF NECESSARY, REPLACE FRONT DRIVE SHIFT FORK SHAFT OIL SEAL (a) Using a screwdriver, remove the oil seal. {b) Using SST, drive in a new oil seal. ‘SST 09608-20011 (c) Apply MP grease to the oil seal lipTF-22 TRANSFER — Transfer oth IF NECESSARY, REPLACE TRANSMISSION REAR OIL SEAL (2) Using a screwdriver, remove the transmission rear oi seal, (b) Using SST, drive in a new oil seal. SST 09316-60010 (c)_ Apply MP grease to the oil seal. IF NECESSARY, REPLACE REAR OUTPUT SHAFT OIL SEAL (a) Using @ screwdriver, remove the oil seal. {b) Using SST, drive in a new oil seal ‘SST 09316-60010 (c) Apply MP grease to the oil seal lip. IF NECESSARY, REPLACE HIGH AND LOW GEAR SELECT LEVER OIL SEAL (a) Using a screwdriver, remove the oil seal,st TRANSFER — Transfer TF23 12. 13. (b) Using SST and hammer, drive in a new oil seal, SST 09608-20011 (c) Apply MP grease to the oil seal lip. IF NECESSARY, REPLACE SPEEDOMETER DRIVEN GEAR OIL SEAL {2) Using SST, pull out the oil seal, SST 09921-00010 {b) Using SST, drive a new oil seal into the sleeve, ‘SST 09201-60011 Oil seal depth: 20 mm (0.79 in.) IF NECESSARY, REPLACE FRONT OUTPUT SHAFT BEARING (a) Remove the oil seal, (See page TF-21) (b) Using a screwdriver, remove the snap ring. (c)_ Using SST, press out the bearing. SST 09316-60010TRANSFER TF24 14, Transfer (d)_ Using SST, press in a new bearing. SST 09316-60010 (e) 7) Install the snap ring. Install a new oil seal. (See page TF-21) IF NECESSARY, REPLACE TRANSFER INPUT SHAFT FRONT BEARING (a) Using a press, press out the bearing. {b) Using SST, press in a new bearing. ‘SST 09316-60010TRANSFER ransfer ASSEMBLY OF TRANSFER (See pages TF-10, 11) 1. INSTALL HIGH GEAR TO REAR OUTPUT SHAFT Using SST, press in the following parts. ‘© High gear © Output shatt front bearing Clutch hub SST 09316-60010 2. INSTALL LOW GEAR TO REAR OUTPUT SHAFT Using SST, press in the following parts, © Clutch sleeve © Low gear © Output shaft rear bearing ‘SST 09316-60010 INSTALL SNAP RING Select snap ring that will allow minimum axial play and install it on the shaft. [ae Fikes ra] 2.30 — 2.35 (0.0906 — 0.0925) 2.60 — 2.65 (0.1024 — 0.1043) 4. INSTALL TRANSFER HIGH AND LOW SHIFT OUTER AND INNER LEVER 5. INSTALL FRONT OUTPUT SHAFT Using SST, press in the front output shaft to the transfer front case. SST 09316-60010TF.26 TRANSFER — Transfer INSTALL TRANSFER INPUT SHAFT TO TRANSFER ADAPTER INSTALL TRANSFER FRONT CASE (2) Apply MP grease to the oil seal. (b) Install the front case with a new gasket to the transfer ‘adapter. (c) Apply liquid sealer to the four bolts, and install and torque as shown. Torque: 17 mm 650 kg-cm (47 ft-lb, 64 N.m) 14 mm 400 kg-cm (29 ft-lb, 39 N-m) (d) Install and torque the other bolt. Torque: 650 kg-cm (47 ft-Ib, 64 N-m) INSTALL SHIFT FORK SHAFT [ Mechanical Shift Type) (a) Install the shift fork shaft into shift fork No. 1. (b) Using @ pin punch and a hammer, drive in the slotted spring pin. NOTE: Use a set of soft jaws in the vise to protect the shift fork. [Electrical Shift Type} (a) Using snap ring pliers, install the snap ring. (b) Install the shift fork, spring and retainer to the shift fork shaft.TRANSFER — Transfer TF.27 9, INSTALL CLUTCH SLEEVE Install the clutch sleeve with the shift fork and shift fork shaft. 10. INSTALL REAR OUTPUT SHAFT FRONT BEARING RETAINER Using a plastic hammer, install the rear output sheft front bearing retainer. 11. INSTALL IDLER GEAR (2) Install a new O-ring on the idler gear shaft front side groove. (b) Install the idler gear shaft to the transfer front case. {c) Install the idler gear thrust washer. NOTE: Be sure that protruding part of washer fits in the case groove. (d) Apply MP grease to the two bearings, (e) Install the two bearings and spacer to the idler gear shaft. (f) Install the idler gear to the idler gear shaft. 12. INSTALL TRANSFER INPUT GEAR Using SST, install the transfer input gear. SST 09309-36033TRANSFER — Transfer 13. INSTALL SPACER AND POWER TAKE-OFF DRIVE | GEAR Install the spacer and power take-off drive gear to the input shaft. —_ 14. INSTALL INPUT SHAFT REAR BEARING Using SST and hammer, drive in the input shaft bearing. SST 09316-60010 fo) 15 INSTALL SHIFT FORK SHAFT | x (2) Install the high and low shift fork shaft into the shift oP fork. | a PD (b) Using a pin punch and @ hammer, drive in the slotted | ~*~ spring pin. NOTE: Use a set of soft jaws in the vise to protect the ‘ \ shift fork. | yA 16. INSTALL REAR OUTPUT SHAFT WITH SHIFT FORK AND SHAFT 17, STICK ON THRUST WASHER Stick the thrust washer to the transfer rear case with MP grease, NOTE: Be sure that protruding part of washer fits in the case groove.TRANSFER ~ Transfer 18. 19. 20. 2a INSTALL TRANSFER REAR CASE (a) Place anew gasket on the front case. {b) Install the rear case, NOTE: Align the high and low shift lever tip with the shift fork shaft groove, (c) Apply liquid sealer to the two bolts, and install and torque as shown. Torque: 650 kg-cm (47 ft1b, 64 Nem) (d)__ Install and torque the other bolts. Torque: 17 mm 650 kg-cm (47 ft-lb, 64 Nom) 14 mm 400 kg-cm (29 ft-lb, 39 Num) INSTALL O-RING AND LOCK PLATE (a) Align the shaft groove to the bolt hole. (bo) Install an O-ring on the shaft groove. (c) Using a plastic hammer, drive in the shaft. {d) Install the lock plate and bolt. Tighten the bolt. Torque: 130 kg-cm (9 ftb, 13 Nem) INSTALL SPEEDOMETER DRIVE GEAR AND SPACER ADJUST REAR OUTPUT SHAFT PRELOAD (a) Install the rear output shaft rear bearing retainer. NOTE: Align the bearing retainer rib with the case. (b) Torque the six bolts. Torque: 350 kg-em (25 ft-lb, 34 N-m) (c)_ Shift the transfer lever to the “N” position.TF-30 TRANSFER —~ Transfer 23. {d) Temporarily install the rear companion flange lock nut. (e) Using a torque meter, measure the rear output shaft preload. (Starting torque) Preload: New bearing 15 — 24.7 kgm (13.0 — 21.4 in-Ib, 1.5 — 2.4 N-m) Reused bearing 7 — 12 kg-cm (6.1 — 10.4 in-Ib, 0.7 — 1.2 Nem) If the preload is not within specification, remove the outer race of the rear output shaft rear bearing with SST. ‘SST 09514-35011 Reselect an adjusting shim. Wark [ Therese worn (ind | Marke | Thickness em find af ots (000s) | 10 | 101003) | a} 04 oo || irio08) | 5] os ooo) = 2 | tzioom | 6 | 06 (oz | 13 | 1300s) | 7 | 07 (oozs | 14 | tajooss) | 2] og (os | 15 | 1.51005) | 8 | op (0035) | | NOTE: The preload will change about 10.0 kg-cm (8.7 in-Ib, 1.0 N-m) with each shim thickness. (f) Remove the rear companion flange lock nut. 22. REMOVE REAR OUTPUT SHAFT REAR BEARING RETAINER INSTALL REAR OUTPUT SHAFT REAR BEARING RETAINER (a) Align the bearing retainer rib with the case rib and install the retainer with a new gasket. (b) Apply liquid sealer to the six bolts. (c)_ Install and torque the bolts. Torque: 350 kg-cm (25 ft-lb, 34 N-m)sst TRANSFER 24, 26. 28. Transfer TF.31 INSTALL FRONT AND REAR COMPANION FLANGE {a) Install the companion flange. {b) Using SST to hold the companion flange, install the companion flange lock nut. SST 09330-00021 Torque: 1,300 kg-cm (94 ft-lb, 127 N-m) {c) Stake the companion flange lock nut. INSTALL TRANSMISSION OUTPUT SHAFT LOCK NUT {a) Using SST to hold the rear companion flange, install the transmission output shaft lock nut. ‘SST 09330-00021 Torque: 1,300 kg-cm (94 ft-lb, 127 N-m) (b) Stake the transmission output shaft lock nut. INSTALL TRANSFER CASE COVER NO.2 (a) Install the transfer case cover No. 2 with a new gasket to the transfer rear case. NOTE: Face the gasket notch downward. (b) Apply liquid sealer to the six bolts. {c) Install and torque the bolts. Torque: 185 kg-cm (11 ft-lb, 15 N-m) INSTALL POWER TAKE-OFF COVER (a) Install the power take-off cover with @ new gasket to the transfer rear case. (b) Apply liquid sealer to the two bolts, and install and torque as shown. Torque: 170 kg-cm (12 ft-lb, 17 N-m) {c) Install and torque the other bolts. Torque: 195 kg-cm (14 ft-lb, 19 N-m) INSTALL SPEEDOMETER DRIVEN GEAR Torque: 130 kg-cm (9 ft-lb, 13 N-m)TF-32 TRANSFER — Tran: 29. 33. INSTALL PLUG, SPRING AND LOCKING BALL (Mechanical Shift Type) Apply liquid sealer to the plugs and install the locking balls, springs and plugs. Torque: 450 kg-cm (33 ft-lb, 44 N-m) (Electrical Shift Type) Apply liquid sealer to the plug and install the locking ball, spring and plug. Torque: 450 kg-cm (33 ft-lb, 44 Nem) INSTALL L4 POSITION SWITCH (ELECTRICAL SHIFT TYPE) Torque: 450 kg-cm (33 ft-lb, 44 N.m) |. INSTALL 4WD INDICATOR SWITCH Using SST, install the 4WD indicator switch. ‘SST 09817-16011 Torque: 450 kg-cm (33 ft-lb, 44 Nem) INSTALL DUST BOOT INSTALL TRANSFER FRONT DRIVE SHIFT LEVER (MECHANICAL SHIFT TYPE) INSTALL DIAPHRAGM CYLINDER (ELECTRICAL SHIFT TYPE) (See page TF-8) INSTALLATION OF TRANSFER (See page MT-35)TRANSFER Electrical Shift Type ELECTRICAL SHIFT TYPE Wiring Diagram Ignition Switch ENGINE Fuse To Taillight Control Relay Battery -——a —5 —— — ———_——__— Transter Control Switch 1 eI Transfer Control Solenoid awo Indicator Light Transfer L4 Position Switch Transfer Control Switch Transfer L4 Position Switch Transter Control Relay 4D Indicator Switch Transfer Control Solenoid 4WD Indicator SwitchTF-34 TRANSFER — Electrical Shift Type Transfer Control Switch INSPECTION OF TRANSFER CONTROL SWITCH INSPECT SWITCH CONTINUITY Inspect the switch continuity between terminals. Terminal " Swit sition ——_ | 2 = ‘ON (Ha) se] OFF (H2) If continuity is not as specified, replace the switch. Transfer L4 Position Switch INSPECTION OF TRANSFER L4 POSITION SWITCH INSPECT SWITCH CONTINUITY (a) Check that there is continuity between terminals when the switch is pushed (transfer is H4 position). {b) Check that there is no continuity between terminals when the switch is free (transfer in H2 position). If continuity is not as specified, replace the switch. Transfer Control Relay INSPECTION OF TRANSFER CONTROL RELAY 1, INSPECT RELAY CONTINUITY (a) Check that there is continuity between terminals 1 and 2. (b) Check that there is continuity between terminals 3 and 4. {c)_ Check that there is no continuity between terminals 1 and 3. If continuity is not as specified, replace the relay. 2, INSPECT RELAY OPERATION Apply the battery voltage across terminals 1 and 2. | ‘Check that there is no continuity between terminals 3 and | 4, | If operation is not as specified, replace the relay.Continuity =¥XETPR) continuity TRANSFER — Electrical Shit ‘4WD Indicator a ‘ ion Switel \" po Tse a Type Transfer Control Solenoid INSPECTION OF TRANSFER CONTROL SOLENOID 1, INSPECT SOLENOID CONTINUITY (a) Check that there is continuity between terminals 1 and 2. (b) Check that there is continuity between terminals 3 and 4. (c) Check that there is no continuity between terminais 1 and 3. If continuity is not as specified, replace the solenoid. 2. INSPECT H2 SOLENOID OPERATION (a) Apply the battery voltage across terminals 1 and 2. Check that air flows from port A to port C. Check that air does not flow from port A to port B. (b) Check that air flows from port A to port B. Check that air does not flow from port A to port C, If operation is not as specified, replace the solenoid. 3. INSPECT H4 SOLENOID OPERATION (a) Apply the battery voltage across terminals 3 and 4. Check that air flows from port A to port C. Check that air does not flow from port A to port B. (b)_ Check that air flows from port A to port B. Check that air does not flow from port A to port C. If operation is not as specified, replace the solenoid. 4WD Indicator Light INSPECTION OF 4WD INDICATOR LIGHT INSPECT INDICATOR LIGHT OPERATION (a) Disconnect the connector of the 4WD_ indicator switch, Connect the terminal 1 of the 4WD indicator switch and body ground. {b) Turn the ignition switch or starter switch on. Check that the bulb lights. If operation is not correct, remove and test the bulb. 4WD Indicator Switch INSPECTION OF 4WD INDICATOR SWITCH INSPECT SWITCH CONTINUITY (a) Check that there is continuity between terminals when the switch is pushed (transfer in 4WD position), (b) Check thet there is no continuity between terminals, when the switch is free (transfer not in 4WD pos: tion). lf continuity is not as specified, replace the switch.PROPELLER SHAFT PRECAUTION........ TROUBLESHOOTING . PROPELLER SHAFT .. Page PR2 PR2 PR2PR2 PROPELLER SHAFT — Precaution, Troubleshooting, Propeller Shaft PRECAUTION Be careful not to grip the propeller shaft tube too tightly in the vise as this will cause deformation. TROUBLESHOOTING Problem Possible couse Remedy Page Noise | Sleeve yoke sotine worn Replace sleeve yoke PRa | Spider bearing worn or stuck Replace spider bearing pad | | Vibration Propeller shaft runout | Replace propetler shaft PR | Propeller shaft imbalance Balance propeller shatt | Sleeve yoke spline stuck | Replace sleeve yoke Pre ba ee | ee =| COMPONENTS Front and Rear Propeller Shaft Rear Propeller Shaft —— Flange Yoke ' * ; el Dust Cover Propeller Shatt Sleeve Yoke [kgom (7b, Nem] : Specified torque\OPELLER SHAFT — Propeller Shaft PRS REMOVAL OF FRONT AND REAR PROPELLER SHAFT DISCONNECT PROPELLER SHAFT FLANGE FROM COMPANION FLANGE ON DIFFERENTIAL (a) Put matchmarks on the flanges. {b) Remove the four bolts and nuts. DISCONNECT PROPELLER SHAFT FLANGE FROM COMPANION FLANGE ON TRANSFER (a) Put matchmarks on the flanges. (b) Remove the four nuts. {c) Remove the propeller shaft. a ] INSPECTION OF PROPELLER SHAFT 1 INSPECT FRONT AND REAR PROPELLER SHAFTS FOR DAMAGE OR RUNOUT If shaft runout is greater than maximum, replace the shaft, Maximum runout: 0.8 mm (0.031 in.) 2. INSPECT SPIDER BEARINGS (a) Inspect the spider bearings for wear or damage. (b) Check the spider bearing axial play by turning the yoke while holding the shaft tightly. Bearing axial play: Less than 0.05 mm (0.0020 in.) If necessary, replace the spider bearing.PR4 PROPELLER SHAFT — Propeller Shaft DISASSEMBLY OF PROPELLER SHAFT (Sea page PR-2) 1 REMOVE SLEEVE YOKE FROM PROPELLER SHAFT (a) Place alignment marks on the sleeve yoke and shaft. {b) Pull out the sleeve yoke from the shaft. REMOVE SPIDER BEARING (a) Put matchmarks on the sleeve yoke and flange. {b) Slightly tep in the bearing outer races. (c)_ Using two screwdrivers, remove the four snap rings from the grooves. {d) Using SST, push out the bearing from the flange. SST 09332-25010 NOTE: Sufficiently raise the part indicated by A so that it does not come into contact with the bearing. (2) Clamp the bearing outer race in a vise and tap off the flange with a hammer. NOTE: Remove the bearing on the opposite side in the same procedure.PROPELLER SHAFT Propeller Shaft PRS (f) Install the two removed bearing outer races to the spider. (9) Using SST, push out the bearing from the yoke. SST 09332-25010 (h) Clamp the outer bearing race in a vise and tap off the yoke with a hammer. NOTE: Remove the bearing on the opposite side in the same procedure. aD cons ASSEMBLY OF PROPELLER SHAFT (See page PR-2) NOTE: When replacing the spider, be sure that the grease fitting assembly hole is facing in the direction shown in figure, DER GREASE FITTING ASSEMBLY DIRECTION No.2 © v0 Yoke em “The figure at left shows the locations saan yee of the grease fittings as sean from the no. © fear, No.1 fPROPELLER SHAF’ 1 Propeller Shaft INSTALL SPIDER BEARINGS (2) Apply MP grease to the spider and bearings. NOTE: Be careful not to apply too much grease (b) Align the matchmarks on the yoke and flange. {c) Fit the new spider into the yoke. {d) Using SST, install the new bearings on the spider. ‘SST 09332-25010 {e) Using SST, adjust both bearings so that the snap ring grooves are at maximum and equal widths. (f) Install two snap rings of equal thickness which will allow 0 — 0.05 mm (0 — 0.0020 in.) axial play. NOTE: Do not reuse the snap rings. ‘Snap ring thicknesses —ihiewen amin) [eater] | va76 — 1.695 (00801 - 0.0800) = 1.525 ~ 1.575 (0.0800 - 0.0820) Brown 1.575 — 1.825 (0.0820 ~ 0.0840) BluePROPELLER SHAFT — Propeller Shaft PRT (a) Using a hammer, tap the yoke until there is no clearance between the bearing outer race and snap ring. (h) Check that the spider bearing moves smoothly. (i) Check the spider bearing axial play. Bearing axial play: Less than 0.05 mm (0.0020 in.) NOTE: Install new spider bearings on the flange side in the procedure described above. 2, INSERT SLEEVE YOKE INTO PROPELLER SHAFT (a) Apply MP grease to the propeller shaft spline and sleeve yoke sliding surface. (b) Align the marks on the sleeve yoke and propeller shaft. (c)__ Insert the propeller shaft into the sleeve yoke. INSTALLATION OF FRONT AND REAR PROPELLER SHAFTS 1. CONNECT PROPELLER SHAFT FLANGE TO COMPANION FLANGE ON TRANSFER (a) Align the matchmarks on the flanges and connect the flanges with four nuts. (b) Torque the nuts. Torque: 750 kg-cm (54 ft-lb, 74 N-m) 2. CONNECT PROPELLER SHAFT FLANGE TO COM- PANION FLANGE ON DIFFERENTIAL (a) Align the matchmarks on the flanges and connect the flanges with four bolts and nuts, {b) Torque the bolts and nuts. Torque: 750 kg-cm (54 ft-lb, 74 N-m)PRS PROPELLER SHAFT — Propeller Shaft 3. APPLY MP GREASE TO GREASE FITTING Using a grease gun, pump the MP grease into each fitting until it begins to flow from around the oil seal.FA FRONT AXLE AND SUSPENSION Page . FA2 FAS FAS FA-12 FA-17 FA28 FAa32 FA32 FA33 FA35 TROUBLESHOOTING ... FRONT WHEEL ALIGNMENT FREE WHEEL HUB .. FRONT AXLE HUB . STEERING KNUCKLE AND AXLE SHAFT FRONT DIFFERENTIAL FRONT SUSPENSION... Coil Spring and Shock Absorber Lateral Control Rod Leading Arm .FA-2 FRONT AXLE AND SUSPENSION — Troubleshooting TROUBLESHOOTING Possiblecause Remedy Page Oil leak at front axle | Oil seals damaged or worn Replace oil seal FAIS Front axle housing cracked Repair as necessary Oil leak st pinion shaft | Oil level too high or wrong grade Drain and replace oil A19 Oil seal worn or damaged Replace oil seal * FA2B Companion flange loose or damaged Tighten or replace flange | RAS Oil level low or wrong grade Drain and replace oil Ao Excessive backlash between pinion and ‘Check backlash RAIO ring oF side gear Ring, pinion or side geers worn or chipped | Inspect gears RAIS Pinion shaft bearing worn Replace bearing RA13 Wheel bearing worn Replace bearing FAIS Differential bearing loose or worn Tighten or replace bearings RA13 Tires worn or improperly inflated Replace tire or inflate tires to AT Proper pressure Alignment incorrect ‘Check front end alignment FAS Wheel bearing adjusted too tightly Adjust wheel bearing FAI3 Front or rear suspension parts loose or Tighten or replace suspension FAS2 broken part Steering linkage loose or worn : Tighten or replace steering sr61 F | linkage ‘Steering gear out of adjustment or broken | Adjust or repair steering gear | SR-3.2046 Vehicle overloaded ‘Check loading ‘Shock absorber worn out Replace shock absorber FA32 Springs weak Replace spring FA32 Tires improperly inflated Inflate tires to proper pressure | AT ‘Shock absorber worn out Replace shock absorber FAS? Front wheel shimmy | Tires worn or improperly Inflated Replace tire or inflate tires to proper pressure a9 Wheels out of balance Balance wheels Steering damper worn out Replace steering damper sRes | ‘Shock absorber worn out Replace shock absorber FAS2 Alignment incorrect Check front end alignment FAS Wheel bearings worn or improperly Replace or adjust wheel FAA adjusted beerings Steering knuckle bearing worn Replace bearing FA18 ‘Steering linkage loose oF worn Tighten oF replace steering SROI linkage Steering gear out of adjustment or broken _| Adjust or repair steering gear $R3,2046: ‘Abnormal tire wear Tires improperly inflated Inflate tie to proper pressure a | Shock absorbers worn out Replace shock absorber FAS2 Alignment incorrect Check toein FASFRONT AXLE AND SUSPENSION — Front Wheel Alignment FA3 FRONT WHEEL ALIGNMENT 1. MAKE FOLLOWING CHECKS AND CORRECT ANY PROBLEMS (a) Check the tires for wear and proper inflation. Correct tire pressure: See page A-7. {b) Check the wheel runout. Lateral runout: Less than 1.2 mm (0.05 in.) (c) Check the front wheel bearings for looseness. (a) Check the front suspension for looseness. (e) Check the steering linkage for looseness. (f) Use the standard bounce test to check that the front absorbers work properly. 2. INSTALL WHEEL ALIGNMENT EQUIPMENT Follow the specific instructions of the equipment manu: facturer. 3. CHECK CAMBER AND KING PIN INCLINATION ‘Camber: 1 +45" King pin inclination: 9°30" = 45° If camber or king pin inclination checks are not within specification, recheck the steering knuckle parts and the. front wheel for bending or looseness, 4. CHECK CASTER Caster: 4°05! + 1° If caster is not as specified, inspect and replace damaged ‘or worn suspension parts.FA4 FRONT AXLE AND SUSPENSION ont Wheel Aligni “== Advance the Vehicle \ WY Ll soos 5. ADJUST TOE-IN (a) Make sure the wheels are positioned straight ahead. (b) Mark the center of each rear tread at spindle height and measure the distance between the marks of the right and left tires. (ec) Advance the vehicle until the marks on the rear side of the tires come to the front. NOTE: The toe-in should be measured at the same point on the tire and at the same level. (d) Measure the distance between the marks on the front side of the tires. Toon mmtin Inspection STD_| Adjustment STD. 22 (—0.0420.08)|—121 (-0.0420.04) Tire 122 (0,0420.08) | 121 (0,040.04) 422 (0.1620.08) | 421 (0.1640.04) (e) Make sure the steering gear is centered (f) Loosen the nuts holding the clamps to the tie rod. (a) Adjust toe-in to the correct value by turning the tie rod. {h) Torque the nuts holding the clamps. Torque: 375 kg-cm (27 ft-lb, 37 N-m) NOTE: © Insure that the lengths of the tie rod ends are the same. ‘© The clamps opening must be positioned at the rear of the tie rod and face within 45° from the verticle axis.FRONT AXLE AND SUSPENSION — Front Wheel Alignment FAS A: Inside B: Outside ADJUST WHEEL ANGLE Remove the caps of the knuckle stopper bolts and check ‘the steering angles, ‘Whee! angle Inside whee! 32°10, Mex. ee = Outside whee! 30 — [at 20° | — TSzteige | inside whee 20°30" vineeid | NOTE: When the steering wheel is fully turned, make sure that the wheel is not touching the body or brake flexible hose. If maximum steering angles differ from the standard value, adjust the wheel angle with the knuckle stopper bolts. Torque: 450 kg-cm (33 ftlb, 44 N-m) If the wheel angle still cannot be adjusted within limits, in- spect and replace damaged or worn steering parts. INSPECT SIDE SLIP WITH SIDE SLIP TESTER Side slip limit: Less than 3.0 mm/m (0.118 in/3.3 ft) If the side slip exceeds the limit, the toe-in or other front wheel alignment may not be correct.FAS FRONT AXLE AND SUSPENSION — Free Wheel Hub FREE WHEEL HUB COMPONENTS Free Wheel Hub Body a ae | Control Handle and SealFRONT AXLE AND SUSPENSION — Free Whee! Hub FAT REMOVAL OF FREE WHEEL HUB 1 REMOVE FREE WHEEL HUB COVER (a) Set the control handle to FREE. (b) Remove the cover mounting bolts and pull off the cover, 2. REMOVE SNAP RING Using snap ring pliers, remove the snap ring. 3, REMOVE FREE WHEEL HUB BODY (a) Remove the mounting nuts. {b) Using a brass bar and a hammer, tap the bolt heads and remove the cone washers, (c) Pull off the free wheel hub body. DISASSEMBLY OF FREE WHEEL HUB 1, REMOVE CONTROL HANDLE FROM FREE WHEEL HUB COVER (a) Using snap ring p! move the snap ring. (b) Remove the control hadie, (c) Remove the steel ball and spring from the control handle. 2, REMOVE INNER HUB AND FREE WHEEL HUB RING FROM FREE WHEEL HUB BODY {a) Using a screwdriver, remove the snap ring. (b) Remove the inner hub and free whee! hub ring.FAB FRONT AXLE AND SUSPENSION ~— Free Wheel Hub REMOVE FREE WHEEL HUB RING FROM INNER HUB (a) Using snap ring pliers, remove the snap ring. (b) Remove the free wheel hub ring and spacer. INSPECTION OF FREE WHEEL HUB INSPECT COVER, HANDLE AND SEAL Temporarily install the handle in the cover and check that the handle moves smoothly and freely. INSPECT BODY AND CLUTCH Check that the clutch moves smoothly in the body. MEASURE THE OIL CLEARANCE BETWEEN THE INNER HUB AND FREE WHEEL HUB RING Oil clearance (A-B): 0.3 mm (0.012 in.)FRONT AXLE AND SUSPENSION — Free Wheel Hub ASSEMBLY OF FREE WHEEL HUB. (See page FA-6) 1, APPLY MP GREASE TO SLIDING SURFACE OF PARTS 2. INSTALL CONTROL HANDLE TO COVER {e) Install the seal, spring and stee! ball to the handle. {b) Insert the handle in the cover and install the snap ring with snap ring pliers. 3. INSTALL TENSION SPRING IN CLUTCH Instal] the tension spring in the clutch with the spring end aligned with the initial groove 4. INSTALL FOLLOWER PAWL TO CLUTCH {a) Place the follower pawl on the tension spring with ‘one of the large tabs against the bent spring end. (b) Place the top ring of the spring on the small tabs. 5. INSTALL CLUTCH AND SPRING INTO COVER (a) Place the spring between the cover and clutch with the large spring end toward the cover. (b) Compress the spring and install the clutch with the paw! tab fit to the handle cam.FA-10 FRONT AXLE AND SUSPENSION — Free Wheel Hub 2 INSTALL SPACER AND FREE WHEEL HUB RING TO INNER HUB (a) Install the spacer and free wheel hub ring to the hub. (b) Using snap ring pliers, install the snap ring. ner INSTALL INNER HUB AND FREE WHEEL HUB RING IN FREE WHEEL HUB BODY (a) Insert the inner hub and free wheel hub ring in the body. (b) Using a screwdriver, install the snap ring. TEMPORARILY INSTALL COVER TO BODY AND CHECK FREE WHEEL HUB {a) Set the control handle and clutch to the free position. {b) Insert the cover in the body and verify that the inner hub turns smoothly. {c) Remove the cover from the body.FRONT AXLE AND SUSPENSION _ Free Wheel Hub INSTALLATION OF FREE WHEEL HUB (See page FA-6) 1. INSTALL FREE WHEEL HUB BODY (a) Place the gasket in position on the front axle hub. (b) Install the free wheel hub body with six cone washes and nuts. Tighten the nuts. Torque: 315 kg-cm (23 ft-lb, 31 N-m) 2. INSTALL SNAP RING (a) Install a bolt in the axle shaft and pull it out. {b) Using snap ring pliers, install the snap ring. {c) Remove the bolt, 3. APPLY MP GREASE TO INNER HUB SPLINES 4, INSTALL FREE WHEEL HUB COVER WITH NEW GASKET (a) Set the contro! handle and clutch to the free position. (b) Place a new gasket in position on the cover. (c) Install. the cover to the body with the follower paw! tabs aligned with the non-toothed portions of the body. (d) Tighten the cover mounting bolts. Torque: 100 kg-em (7 ft-lb, 10. N-m)FA-12 FRONT AXLE AND SUSPENSION — Front Axle Hub FRONT AXLE HUB COMPONENTS Outer Bearing 8 oe] Thrust Wother @ Oil Seal ab with Disc parts atts @ Lock Washer W007, 10) 315 (23. 31)) Wheel Hub Flange and Gasket Snap Ring kgem (fib, Nm)] +: Specified torque © 1 Non aveabie par ueFRONT AXLE AND SUSPENSION — Front Axle Hub FA-13 Front Axle Hub DISASSEMBLY OF FRONT AXLE HUB 1. REMOVE DISC BRAKE CYLINDER {a) Using SST, disconnect the brake tube. SST 09751-36011 (b) Remove the brake caliper. 2, REMOVE FLANGE OR FREE WHEEL HUB NOTE: For the free wheel hub. (See page FA-7) {a) Remove the cap from the flange. {b) Using snap ring pliers, remove the snap ring. (c) Remove the mounting nuts. (d) Using a brass bar and a hammer, tap the bolt heads and remove the cone washers. (e) Install and tighten the two bolts, and remove the flange. 3. REMOVE AXLE HUB WITH DISC (a) Using a screwdriver, release the lock washer. (b) Using SST, remove the lock nut. SST 09607-60020 (c) Remove the lock washer and adjusting nut. {d) Remove the axle hub with the dis.