Transfer Assembly

TRANSFER ASSEMBLY

3VZ-E/R150F:

22R-E/G58,A340F:

1. INSTALL PLANETARY RING GEAR
(a) Install the planetary ring gear to the front case.

HINT: Ensure that the ring gear is installed in the correct direction.

(b) Install the pin and spring.
(c) Apply liquid sealer to the plug.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
(d) Install and torque the plug.
Torque: 19 Nm (190 kgf-cm, 14 ft-lbf)

(e) Install the snap ring.

HINT: Ensure that the end gap of the snap ring is not aligned with the upper side of the case.

2. INSTALL INPUT SHAFT TO PLANETARY GEAR ASSEMBLY
(a) Apply gear oil to the thrust bearing and race.
(b) Install the race and thrust bearing.

3. INSTALL THRUST BEARING AND INPUT SHAFT STOPPER
(a) Apply gear oil to the thrust bearing and race.
(b) Install the race and thrust bearing.

4. INSTALL SNAP RING
(a) Select a snap ring that will allow 0.05-0.15 mm (0.0020-0.0059 in.) axial play.

(b) Using a snap ring expander, install the snap ring.

5. INSTALL NEEDLE ROLLER BEARING INTO INPUT SHAFT
(a) Apply gear oil to the needle roller bearing.
(b) Install the needle roller bearing into the input shaft.

6. INSTALL LOW GEAR SPLINE PIECE
(a) Install the low gear spline piece to the planetary carrier.

(b) Install the snap ring.

HINT: Ensure that the end gap of the snap ring is not aligned with the cutout portion of the planetary carrier.

7. INSTALL PLANETARY GEAR ASSEMBLY TO FRONT CASE
(a) Install the planetary gear assembly with the input shaft.

HINT: If necessary, heat the front case to about 70°C (158°F).

(b) Install the snap ring.

8. INSTALL OIL PUMP DRIVE GEAR

9. INSTALL OIL PUMP BODY ASSEMBLY
(a) Install the oil pump body assembly.
(b) Install and torque the 3 bolts. Torque: 11 N~m (115 kgf.cm. 8 ft.Ibf)

10. INSTALL SEPARATOR WITH OIL STRAINER
(a) Coat a new 0-ring with gear oil and install it to the oil strainer pipe.
(b) Install the separator with the oil strainer.
(c) Install and torque the 3 bolts.
Torque: 18 Nm (185 kgf-cm, 13 ft-lbf)

11. INSTALL REAR OUTPUT SHAFT, DRIVEN SPROCKET AND CHAIN
(a) Apply MP grease to the synchronizer ring (for M/T).
(b) Align the synchronizer ring slots with the shifting keys, and install it on the high and low clutch hub.

(c) Assemble the rear output shaft, driven sprocket and chain.
(d) Mount the rear case in the vise.

NOTICE: Be careful not to damage the sealing surface.

(e) Using a plastic hammer, tap the rear case with pushing the rear output shaft and driven sprocket.

HINT: If necessary, heat the rear case to about 70°C (158°F).

(f) Using a snap ring expander, install the snap ring.

12. INSTALL HIGH AND LOW FORK SHAFT. FORK AND STOPPER
(a) Place the high and low shift fork into the groove of the hub sleeve.

HINT: Ensure that the shift fork is installed in the correct direction.

(b) Install the fork shaft to the rear case through the shift fork and stopper.

13. INSTALL FRONT DRIVE FORK SHAFT. FORK AND SPRING
(a) Apply gear oil to the straight pin, and install it into the case hole.

(b) Place the front drive shift fork into the groove of the hub sleeve.

HINT: Ensure that the shift fork is installed in the correct direction.

(c) Install the spring to the fork shaft.
(d) Install the fork shaft to the rear case through the shift fork and stopper.

(e) Using a pin punch and hammer, drive in the 2 slotted spring pins.

HINT: When installing the pin in the front drive fork shaft, push the shaft towards the rear case and install the pin while the spring is compressed.

14. INSTALL STRAIGHT SCREW PLUGS, SPRINGS AND LOCKING BALLS
(a) Install the ball and spring into the both holes.

(b) Apply liquid sealer to the plugs.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
(c) Using a hexagon wrench, install and torque the 2 screws.
Torque: 19 Nm (190 kgf-cm, 14 ft-lbf)

15. ASSEMBLE FRONT CASE AND REAR CASE
(a) Apply FIPG to the rear case, as shown.
FIPG: Part No.08826-00090, THREE BOND 1281 or equivalent

(b) Shift the high and low hub sleeve to low side (rear side).
(c) Assemble the front case and rear case.
(d) Install and torque the 1 2 bolts.
Torque: 37 Nm (380 kgf-cm, 27 ft-lbf)

16. INSTALL SPEEDOMETER DRIVE GEAR
(a) Install the ball on the rear output shaft.
(b) Install the speedometer drive gear.

HINT: Make sure to install the speedometer drive gear in the correct direction.

17. INSTALL EXTENSION HOUSING
(a) Apply FIPG to the extension housing. as shown.
FIPG: Part No.08826-00090. THREE BOND 1281 or equivalent

(b) Install the extension housing to the rear case.
(c) Apply liquid sealer to the bolts.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
(d) Install and torque the 5 bolts.
Torque: 11 Nm (115 kgf-cm, 8 ft-lbf)

18. INSTALL FRONT COMPANION FLANGE

HINT: Front companion flange bolts are silver.

(a) Apply gear oil to the companion flange inner surface.
(b) Install the front companion flange to the driven sprocket shaft.
(c) Using SST to hold the flange, install the companion flange lock nut. SST 09330-00021
Torque: 118 Nm (1,200 kgf-cm, 87 ft.-lbf)
(d) Stake the lock nut.

19. INSTALL REAR COMPANION FLANGE

HINT: Rear companion flange bolts are black.

Install the rear companion flange in the same way as the front companion flange.

20. 3VZ-E/R150F:
INSTALL CONTROL RETAINER
(a) Install the select return spring to the control retainer.

(b) Remove the gasket and install a new one to the control retainer.
(c) Install the control retainer.
(d) Install and torque the 4 bolts.
Torque: 18 Nm (185 kgf-cm, 13 ft-lbf)

21. 22R-E/G58, A340F:
INSTALL UPPER COVER AND BREATHER HOSE DEFLECTOR
(a) Remove the gasket and install a new one to the case cover.
(b) Install the upper cover and breather hose deflector.
(c) Install and torque the 4 bolts.
Torque: 18 Nm (185 kgf-cm, 13 ft-lbf)

22. INSTALL FRONT RETAINER
(a) Remove the gasket and install a new one to the front retainer.
(b) Install the front retainer.
(c) Apply liquid sealer to the bolts.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent.
(d) Install and torque the 7 bolts.
Torque: 11 Nm (115 kgf-cm, 8 ft-lbf)

23. 22R-E/ G58, A340F:
INSTALL SHIFT GEAR HEAD NO.1 AND NO.2
(a) Install 2 shift gear heads.
(b) Using a pin punch and hammer, drive in the 2 slotted spring pins.
24. CHECK FOLLOWING ITEMS:
- Check to see that the input shaft and output shafts rotate smoothly.
- Check to see that shifting can be made smoothly to all positions.
25. INSTALL TRANSFER INDICATOR SWITCH
Torque: 37 Nm (380 kgf-cm, 27 ft-lbf)
26. INSTALL NO.1 SPEED SENSOR
(a) Install No.1 speed sensor.
(b) Install and torque the bolt.
Torque: 11 Nm (115 kgf-cm. 8 ft-lbf)
27. 22R-E/ A340F:
INSTALL TRANSFER L4 AND NEUTRAL POSITION SWITCH
Torque: 37 Nm (380 kgf-cm. 27 ft-lbf)