Note: Before assembly, clean all parts in solvent, dry them and apply grease to the contact areas.
1. Install the magnet (A) and differential (B) assembly into the clutch housing.
2. Install the 28mm spring washer (A) and 28mm washer (B) onto the ball bearing (C). Observe the installation direction of the spring washer (A).
3. Wrap the splined portion (D) of the secondary shaft with electrical tape to protect the oil seal. Insert the secondary and intermediate (E) shafts into the shift forks (F) and install them as an assembly into the clutch housing.
4. Install the reverse shift fork.
5. Install the reverse idler gear (A) and reverse gear shaft (B), aligning the mark (C) with the hole (D) for the reverse gear shaft.
6. Install the reverse locking cam.
7. Select the 72 mm adjusting washer (A) of the required size based on the measurements obtained during the secondary shaft thrust clearance adjustment (see above). Install the oil trough (B), oil transfer plate M and the 72 mm adjusting washer into the gearbox housing (C).
8. Remove dirt and oil from the sealing surfaces of the gearbox housing. Apply sealant (08X70-K0234M) onto the sealing surface. To prevent oil leakage, seal the bolt holes around their entire circumference.
Note: If more than 5 minutes have passed since applying the sealant, apply it again and reassemble the crankcases. Allow the sealant to cure for at least 20 minutes after assembly before refilling the transmission with oil.
9. Install 14x20 dowel pins (A).
10. Install the conical ring (B) as shown in the figure. Place the gearbox housing on the clutch housing, carefully aligning the shafts.
11. Lower the gearbox housing by spreading the ends of the 72 mm snap ring (C). Release the snap ring so that it fits into the intermediate shaft bearing groove.
12. Ensure that the 72mm snap ring is securely seated in the intermediate shaft bearing groove.
Size [a] after installation: 3.3-6.0 mm
13. Apply sealant to the 32 mm (D) plug thread (08X70-K0234M) and screw it into the gearbox housing.
14. Install hanger brackets A and B to the gearbox and tighten the 8mm flange bolts finger tight.
15. Tighten the 8mm flange bolts in a cross pattern in several passes.
16. Remove dirt and oil from the sealing surfaces of the gear shift lever cover. Apply sealant (08X70-K0234M) onto the sealing surface.
Note: If more than 5 minutes have passed since applying the sealant, apply it again and reassemble the components. Allow the sealant to cure for at least 20 minutes after assembly before refilling the transmission with oil.
17. Install the 8x14mm dowel pins (A), clutch pipe clamp bracket (B) and shift lever assembly (C).
18. Apply sealant (08X70-K0234M) onto the thread of the locking bolt (D) and screw it into the gearbox housing.
19. Screw in the plug (A) into the drain hole, the plug (B) into the filler hole and the 10 mm flange bolt (C), using new washers.
20. Install the steel balls, springs and tighten the lock bolts (A), using new washers.
21. Apply sealant (08X70-K0234M) onto the thread of the reversing light switch (B) and screw it into the gearbox housing.
22. Screw in the vehicle speed sensor (VSS) (A) and install the O-ring (B).
23. Install the O-ring (A) and install the left cover (B). (2WD model)
24. Install the 10x20mm dowel pin (A), O-ring (B) and transfer case assembly (C). (4WD model)
