Caution: When removing and installing the transfer case assembly, do not allow dust or other foreign objects to enter the gearbox.
1. Install a new O-ring onto the transfer case assembly.
2. Thoroughly clean the areas where the transfer case assembly and transmission meet with solvent or carburetor cleaner and dry with compressed air. Then apply transmission fluid to the contact areas.
3. Install the transfer case assembly onto the gearbox.
4. Install the rear stiffener.
1. REAR STIFFENER
2. 8x1.25 mm, 24 Nm (2.4 kgf/m)
3. 10x1.25 mm, 44 Nm (4.5 kgf/m)
4. TRANSFER CASE ASSEMBLY
5. O-RING. Replace
6. REFERENCE PIN
5. Attach the propeller shaft to the transfer case assembly, aligning the marks.
1. 8x1.25 mm, 32 Nm (3.3 kgf/m). Replace
2. TAGS
3. TRANSFER CASE ASSEMBLY
4. TRANSFER CASE CONNECTING FLANGE
5. CARDAN SHAFT
6. Install the exhaust pipe A.
1. GASKET. Replace
2. EXHAUST PIPE A
3. 10x1.25 mm, 32 Nm (3.4 kgf/m). Replace
4. GASKET. Replace
5. 8x1.25 mm, 16 Nm (1.6 kgf/m). Replace
6. 10x1.25 mm, 54 Nm (5.5 kgf/m). Replace
7. Install the rear support beam.
1. REAR LOAD-BEARING BEAM
2. 12x1.25 mm, 64 Nm (6.5 kgf/m)
3. 10x1.25 mm, 38 Nm (3.9 kgf/m),
4. 12x1.25 mm, 64 Nm (6.5 kgf/m)
8. Install the mudguard.
1. CLAMP
2. MUD GUARD
3. 6x1.0 mm, 12Nm (1.2 kgf/m)
9. Fill the gearbox with transmission fluid (see above).
10. Start the engine and warm it up to normal operating temperature (the radiator fan will turn on). Stop the engine and check the fluid level.