Part 2

27. INSTALL TRANSMISSION CASE
a. Place a new gasket in position on the intermediate plate.
b. Assemble the transmission case and intermediate plate.

c. Using snap ring pliers, install the snap ring.

d. Install the detent ball and spring into each hole.
e. Apply liquid sealer on the threads and under the screw plug heads.
Sealant: Part No 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
f. Using SST, install and torque the three screw plugs.
SST 09313-30021

Torque: 220 kg-cm (16 ft-lb, 22 N-m)

28. INSTALL REVERSE SHIFT ARM PIVOT
a. Insert the shift arm pivot through the reverse shift arm.
b. Torque the shift arm pivot.

Torque: 300 kg-cm (22 ft-lb, 29 N-m)

29. (Z54F)
INSTALL SNAP RINGS
Using a plastic-faced hammer tap the snap ring on No.1 and No.2 shift fork shafts.

30. INSTALL SHIFT HEADS (NO.1, NO.2, AND NO.3)
a. Slide the shift head onto each shift fork shaft.

b. Align the pin holes of the shift head and shift fork shaft.
c. Using a pin punch and hammer, tap in the slotted spring pin until it is flush with the shift fork.

31. INSTALL SPEEDOMETER DRIVE GEAR
(Z53)
a. Install the locking ball in the output shaft.
b. Slide the drive gear onto the shaft. Align the locking ball groove of the drive gear with the locking ball.
c. Using snap ring pliers, install the snap ring.

(Z54F)
a. Install the locking ball in the output shaft.
b. Slide the drive gear onto the shaft. Align the locking ball groove of the drive gear with the locking ball.
c. Using a plastic-faced hammer, tap in the snap ring.

32. (Z54F)
INSTALL THRUST WASHER OF EXTRA LOW GEAR
a. Using a plastic-faced hammer, tap in the snap ring.
b. Install the locking ball in the output shaft.
c. Slide the thrust washer onto the shaft. Align the locking ball groove of the thrust washer with the locking ball.

33. (Z54F)
CHECK EXTRA LOW GEAR THRUST CLEARANCE
a. Install the needle roller bearings, extra low gear and transfer clutch hub with the snap ring.
b. Using a feeler gauge, measure the extra low gear thrust clearance.

Standard clearance: 0.180 - 0.430 mm (0.0070 - 0.0169 in.)

c. Remove the snap ring, transfer clutch hub, extra low gear and needle roller bearing.

34. (Z54F)
ASSEMBLE EXTRA LOW GEAR AND NO.4 HUB SLEEVE
a. Install the extra low gear and shifting keys to the hub sleeve.
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.

35. (Z54F)
INSTALL REVERSE RESTRICT PIN
a. Install the reverse restrict pin to the transfer adaptor.
b. Align the pin holes of the reverse restrict pin and transfer adaptor.
c. Using a pin punch and hammer, tap in the slotted spring pin.

d. Apply liquid sealer on the threads and under the screw plug head.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
e. Using SST, install and torque the screw plug.
SST 09313-30021

Torque: 220 kg-cm (16 ft-lb, 22 N-m)

36. (Z54F)
INSTALL TRANSFER SHIFT LEVER SHAFT AND REAR DRIVE SHIFT LINK LEVER
a. Install the shift lever shaft and shift link lever together with the plate washer.

b. Align the cutouts of the lever lock pin and shift lever shaft.
c. Install the lever lock pin, spring washer and nut.
Torque the nut.

Torque: 130 kg-cm (9 ft-lb, 13 N-m)

37. (Z54F)
INSTALL TRANSFER ADAPTOR AND EXTRA LOW GEAR
a. Apply gear oil to the output shaft.
b. Slide the two needle roller bearings onto the output shaft.
c. Place a new gasket in position on the transmission case.

d. Install No.4 shift fork to No.4 hub sleeve.
e. Place the extra low gear assembly and No.4 hub sleeve into position in the transfer adaptor.

f. Install the select lever on the transfer adaptor.
g. Install the transfer adaptor.
Turn the select lever and insert the tip into the shift head groove.
h. Apply liquid sealer to the bolt threads.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent

i. Install and torque the nine bolts.

Torque: 260 kg-cm (19 ft-lb, 25 N-m)

j. Install the reverse restrict pin and spring with the plug.

Torque: 410 kg-cm (30 ft-lb, 40 N-m)

38. INSTALL NO.4 SHIFT FORK SHAFT AND NO.4 SHIFT HEAD
a. Using a magnetic finger, install the interlock pin.

b. Using a plastic-faced hammer, tap in the snap ring.

c. Install No.4 shift fork shaft.

d. Install No.4 shift head.

e. Align the pin holes of No.4 shift fork and No.4 shift fork shaft.
f. Using a pin punch and hammer, tap in the slotted spring pin until it is flush with the shift fork.

g. Apply liquid sealer on the threads and under the screw plug head.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
h. Using SST, install and torque the screw plug.
SST 09313-30021

Torque: 250 kg-cm (18 ft-lb, 25 N-m)

i. Install No.4 shift head mount bolt together with a new lock plate.

Torque: 125 kg-cm (9 ft-lb, 12 N-m)

j. Stake the lock plate.

k. Install the detent ball, spring and spring seat.
l. Install a new gasket and the transfer case cover with the four bolts.
Torque the bolts.

Torque: 195 kg-cm (14 ft-lb, 19 N-m)

39. INSTALL TRANSFER CLUTCH HUB
a. Slide No.4 synchronizer ring and transfer clutch hub. Align the synchronizer ring slots with the shifting keys.
b. Using snap ring pliers, install the snap ring.

40. INSTALL OIL PUMP DRIVE SHAFT
a. Temporarily install the input shaft.

b. Cover the tip of the input shaft with a shop cloth, and secure it with pliers, then install and torque the oil pump drive shaft.

Torque: 130 kg-cm (9 ft-lb, 13 N-m)

NOTE: The oil pump drive shaft has left-hand threads.

c. Remove the input shaft.

41. ASSEMBLE TRANSFER SHIFT FORK AND TRANSFER SHIFT FORK SHAFT
a. Assemble the transfer shift fork and transfer shift fork shaft.
b. Align the pin holes of the transfer shift fork and transfer shift fork shaft.
c. Using a pin punch and hammer, tap in the slotted spring pin.

42. INSTALL TRANSFER SHIFT FORK ASSEMBLY AND TRANSFER HUB SLEEVE
a. Place the transfer shift fork on the transfer hub sleeve.

b. Install the transfer shift fork assembly and transfer hub sleeve together.
Connect the transfer shift lever shaft into the transfer shift fork groove.

c. Install the detent ball, spring and spring seat.
d. Apply liquid sealer on the threads and under the screw plug head.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
e. Using SST, install and torque the screw plug.
SST 09313-30021

Torque: 250 kg-cm (18 ft-lb, 25 N-m)

43. INSTALL TRANSFER OUTPUT SHAFT AND OIL PUMP ROTORS
a. Install the following parts:
1. Oil baffle
2. Transfer output shaft
3. Oil pump rotors
b. Install the oil pump cover with the three bolts.
Torque the bolts.

Torque: 195 kg-cm (14 ft-lb, 19 N-m)

44. (Z53)
INSTALL REVERSE RESTRICT PIN
a. Install the reverse restrict pin to the extension housing.
b. Align the pin holes of the reverse restrict pin and extension housing.
c. Using a pin punch and hammer, drive in the slotted spring pin.

45. (Z53)
INSTALL SELECT LEVER AND SHIFTING ROD END
a. Install the select lever and shifting rod to the extension housing.
b. Align the cutouts of the lever lock pin and select lever.
c. Install the lever lock pin, spring washer and nut.
Torque the nut.

Torque: 195 kg-cm (14 ft-lb, 19 N-m)

46. INSTALL EXTENSION HOUSING
(Z53)
a. Place a new gasket in position on the transmission case.
b. Install the extension housing.
Turn the tip into the shift head groove.
c. Apply liquid sealer to the bolt threads.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent

d. Install and torque the nine bolts.

Torque: 260 kg-cm (19 ft-lb, 25 N-m)

e. Install two reverse restrict pins, springs and plugs.
Torque the plugs.

Torque: 410 kg-cm (30 ft-lb, 40 N-m)

(Z54F)
a. Place a new gasket in position on the transfer adaptor.
b. Install the extension housing and shift lever housing together.
c. Apply liquid sealer to the bolt threads.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
d. Install and torque the nine bolts.

Torque: 260 kg-cm (19 ft-lb, 25 N-m)

e. Install the mount bolt of the shift lever housing together with a new lock plate.
Torque the bolt.

Torque: 340 kg-cm (25 ft-lb, 33 N-m)

f. Stake the lock plate.

g. Install a new gasket and the shift lever retainer with the six bolts.
Torque the bolts.

Torque: 195 kg-cm (14 ft-lb, 19 N-m)

h. Install and torque the reverse restrict pin.

Torque: 410 kg-cm (30 ft-lb, 40 N-m)

47. INSTALL FOLLOWING SWITCH:
a. Back-up light switch (brass color).
b. (Z54F)
4WD indicator switch (chrome color).
c. (Z54F)
Extra low gear (EL) indicator switch.
48. INSTALL SPEEDOMETER DRIVEN GEAR
49. INSTALL MOUNTING INSULATOR