Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Nissan Frontier 1998-2002 Approved Nissan Frontier 2000 KA24DE TF
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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 1 Installing center case oil seal
1 (J25273) 2 Installing rear oil seal
2 (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 1 Installing main gear bearing
1 (J25742-3) (Use with ST30611000)
2 (J34339) 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 1 Installing mainshaft rear bearing HA
2 Installing L & H hub
1 a: 50 mm (1.97 in) dia.
b: 42 mm (1.65 in) dia. EL
c: 180 mm (7.09 in)
2 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.
q Before installing, apply multi-purpose grease to seal lip.
6. Install companion flange.
AMT086
7. Tighten companion flange nut.
: 226 - 324 N m (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
q Be careful not to damage cross shaft.
MA
EM
LC
SMT491A
5. Install shift shaft oil seal. EC
q 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
q 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.
q 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
q Apply sealant to mating surface of transfer case to transmis-
sion.
q Use genuine anaerobic liquid gasket, Three Bond TB1215,
Loctite Part No. 51813 or equivalent.
SMT495A
q Tighten bolts securing transfer.
Tightening torque
Bolt No. l mm (in)
N m (kg-m, ft-lb)
1 31 - 41 (3.2 - 4.2, 23 - 30) 45 (1.77)
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.
q 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.
q 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)
q 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.
q 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)
q 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.
q 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
q Check gears for excessive wear, chips or cracks. FE
q Check shaft for cracks, wear or bending.
q Check coupling sleeve for wear or damage.
CL
MT
SMT348A
Baulk ring AT
q Check baulk ring for cracks or deformation.
TF
PD
FA
SMT349A
q 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
q 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.
q 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
q Using a gear puller, remove front drive shaft front and rear
bearings.
SMT437C
INSPECTION
Sprocket and shaft
q Check sprocket for excessive wear, chips or cracks.
q Check shaft for cracks or wear.
Bearing
q Make sure bearings roll freely and are free from noise, cracks,
pitting or wear.
SMT357A
ASSEMBLY
q 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
q Remove front sub-gear, dish plate and spacer.
EM
LC
AMT093
2. Press out counter gear rear bearing. EC
q Remove rear sub-gear, dish plate and spacer.
FE
CL
MT
SMT301A
INSPECTION AT
Gear and shaft
q Check gears for excessive wear, chips or cracks. TF
q Check shaft for cracks or wear.
Bearing PD
q 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
q Always replace with a new one whenever it has been
removed.
SMT306A
INSPECTION
Gear and shaft
q Check gears for excessive wear, chips or cracks.
q Check shaft for cracks or wear.
Bearing
q 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.
q 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
q Use a screwdriver to pry out old seal.
q Be careful not to damage case. CL
q Always replace with a new one whenever it has been removed.
MT
SMT310A
Installation AT
q Install new shift shaft oil seal until flush with case.
q Before installing, apply multi-purpose grease to seal lip. TF
PD
FA
SMT311A
RA
Front Case Cover
COVER OIL SEAL
BR
Removal
q Drive out old seal from inside of front case cover.
q Be careful not to damage front case cover. ST
RS
SMT312A
BT
Installation
q Install new front case cover oil seal until it stops.
q Before installing, apply multi-purpose grease to seal lip. HA
EL
IDX
SMT313A
TF-23
REPAIR FOR COMPONENT PARTS
Bearing Retainer
OIL CATCHER
Removal
q Drive out oil catcher from inside of bearing retainer.
q Be careful not to damage bearing retainer.
SMT314A
Installation
q Install oil catcher until it stops.
q Be careful not to damage or distort oil catcher or bearing
retainer.
q Before installing, apply multi-purpose grease to seal lip.
SMT315A
Center Case
REMOVAL
Center case oil seal
q Remove center case oil seal.
SMT863D
INSTALLATION
Center case oil seal
q Install center case oil seal.
SMT864D
Rear Case
REAR OIL SEAL
Removal
q Pull out rear oil seal.
AMT094
TF-24
REPAIR FOR COMPONENT PARTS
Rear Case (Cont'd)
Installation GI
q Install new rear oil seal until it stops.
q Before installing, apply multi-purpose grease to seal lip.
MA
EM
LC
SMT317A
AIR BREATHER EC
Install as shown in illustration.
q Use genuine thread locker, Three Bond TB1324, Loctite
FE
271 or equivalent.
CL
MT
SMT799A
Shift Control Components AT
INSPECTION
q Check contact surface and sliding surface for wear, scratches, TF
projections or other faulty conditions.
PD
FA
SMT360A
L & H SHIFT ROD & FORK RA
q 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
q 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)
q 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.
q Use genuine anaerobic liquid gasket, Three Bond TB1215,
Loctite Part No. 51813 or equivalent. FE
q These ten bolts should be coated with sealant.
Bolts A:
: 16 - 21 N m (1.6 - 2.1 kg-m, 12 - 15 ft-lb) CL
Bolts B:
: 19 - 24 N m (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
q 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.
q 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.
q Apply sealant to switch and plugs.
q 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.
q Apply ATF to mainshaft front bearing.
SMT406A
b. Install bearing retainer.
: 16 - 21 N m (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.
q 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
q 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.
q 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
q Pay attention to the direction of the coupling sleeve.
BR
ST
RS
SMT412A
g. Install shifting inserts and spread spring.
BT
q 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.
q 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.
q Steel ball is the smallest check ball for this unit.
SMT415A
l. Install low gear and bearing onto mainshaft.
q Apply ATF to needle bearing.
SMT340A
m. Install L & H hub and snap ring onto mainshaft.
q Pay attention to the direction of L & H hub.
SMT760A
TF-32
ASSEMBLY
n. Measure low gear end play. GI
q 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.
q 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.
q Use genuine anaerobic liquid gasket, Three Bond TB1215,
Loctite Part No. 51813 or equivalent. HA
11. Install 4WD switch and vehicle speed sensor.
q Apply sealant to switch threads. EL
q 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
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