Warning! When removing and installing the transfer case assembly, do not allow dust or other foreign matter to enter the transmission.
1. Install a new O-ring on the transfer case assembly.
2. Thoroughly clean the areas at the junction of the transfer case assembly and transmission with solvent or carburetor cleaner and dry with compressed air. Then apply transmission fluid to the contact areas.
3. Install the transfer case assembly to 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 BOX ASSEMBLY
5. O-ring. Replace
6. REFERENCE PIN
5. Attach the cardan shaft to the transfer box assembly, matching the marks.
1. 8x1.25 mm, 32 Nm (3.3 kgf/m). Replace
2. LABELS
3. TRANSFER BOX ASSEMBLY
4. TRANSFER BOX CONNECTING FLANGE
5. Cardan shaft
6. Install 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 CARRIER
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 mudguard.
1. CLAMP
2. MUD SHIELD
3. 6x1.0mm, 12Nm (1.2 kgf/m)
9. Fill the transmission with transmission fluid (see above).
10. Start the engine and warm it up to normal operating temperature (radiator fan turns on). Stop the engine and check the fluid level.