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Group 24
Transfer

' 98 Minor Change

Table of Contents

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Pub No. TWSE9501-224

 24

GROUP 24 TRANSFER < FG >

SPECIFICATIONS ........................................................................... 24- 2

STRUCTURE AND OPERATION .................................................... 24- 2

TROUBLESHOOTING ..................................................................... 24- 4

REMOVAL AND INSTALLATION OF TRANSFER ASSEMBLY ..... 24- 6

FRONT DRIVE ................................................................................. 24- 10

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IDLER GEAR AND REAR DRIVE ................................................... 24- 16

TRANSFER CONTROL ................................................................... 24- 22

24-1
SPECIFICATIONS/STRUCTURE AND OPERATION
SPECIFICATIONS
Item Specifications
Model TF3
Gear ratio HIGH 1.090
LOW 1.987
Gear oil Oil quantity L {qts.} 3.0 {3.2}
Dry mass (including transmission body) kg {lb} Approximately 190 {420}
Control Front drive and HIGH-LOW switching floor change remote control

STRUCTURE AND OPERATION

Transfer Body
1 Transmission main shaft
1 2
2 Drive shaft gear
3 Transfer idler gear
4 Transfer idler shaft

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5 Output shaft
6 Output shaft LOW gear
7 Output shaft HIGH gear
3 8 Front drive hub and sleeve
9 Front drive shaft

8
7 6 27272

1 2 The transfer functions as both the distributer for four-wheel

drive and as the sub-transmission with a reduction device.
This transfer is a three-shaft constant-mesh type.
3 HIGH/LOW changeover and front drive ON/OFF are control-
7
4 led by a transfer control lever in the cab.
8 6
9
5
To front axle To rear axle

ON OFF
HIGH LOW
Front drive 06389
HIGH/LOW switching

24-2
 24
Transfer Control

2
3

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4
27273

1 Transfer control lever 3 Transfer

2 2H/4H control cable 4 HIGH/LOW control cable

Move the transfer control lever 1 from left to right to change-over between two-wheel drive and four-wheel drive. Forward
and backward movement changes between HIGH and LOW.

Transfer Control Electric Circuit

1 Fuse box
1 2 2 Meter cluster
3 Transfer four-wheel drive indicator
3 4 lamp
4 Transfer LOW indicator lamp
5 Transfer LOW switch
6 Transfer four-wheel drive switch

Shift transfer control lever to 4L and transfer

LOW switch 5 comes ON and transfer LOW
indicator lamp 4 in the meter cluster 2 lights
up. Shift transfer control lever to 4H and trans-
fer four-wheel drive switch 6 comes ON and
transfer four-wheel drive indicator lamp 3 lights
up.

6 5
27274

24-3
TROUBLESHOOTING

Symptoms

Gears fail to disengage on HIGH/LOW changeover

Gears fail to disengage on front drive changeover
Gears fail to engage at HIGH/LOW changeover
Gears fail to engage at front drive changeover

Front drive is engaged, but indicator is not lit

Front drive is not engaged, but indicator is lit

Gears slip out while cruising in front drive

LOW is selected, but indicator is not lit

LOW is not selected, but indicator is lit

Gears slip out while cruising
Noise while cruising

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Possible causes
Front drive shaft and constant sleeve splines worn ●
Hub and HIGH/LOW constant sleeve splines worn ●
Idler shaft bearing worn or damaged ●
Output shaft bearing worn or damaged ●
Drive shaft needle bearing worn or damaged ●
Transfer Gears damaged ●
body faulty Output shaft LOW gear and HIGH gear ●
backlash excessive
Gear oil insufficient ●
Gear oil viscosity unsuitable ●
Constant sleeve and dog clutch cracked ● ●
HIGH/LOW constant sleeve and hub cracked ● ●
Shift rail bent ● ●
Shift rail friction movement poor ● ●
Control mechanism Shift fork bent ● ●
faulty Shift fork claw worn ● ●
Steel ball and shift rail poppet groove worn ●
Poppet spring fatigued or cracked ●
Transfer control Control cable faulty ● ● ● ●
system faulty LOW switch faulty ● ●
Transfer four-wheel drive switch faulty ● ●
Wiring broken or connection poor ● ●

24-4
 MEMO
24

24-5
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REMOVAL AND INSTALLATION OF TRANSFER ASSEMBLY

Ê
9
Ù A
- 1
- 4 Ê
14 12 - -
Ù

* Ê 6 Ê
8 7 Ù Ù

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13
Ê 11

27275

● Disassembly sequence
1 Bolt 10 Oil seal
2 Air breather 11 Transfer assembly Õ P24-10, 16
3 Needle bearing 12 Distance pipe
4 Transfer input rear cover 13 Bolt
5 Lock nut 14 Extension spacer
6 O-ring
7 Drive shaft gear A : Positioning pin
8 Bolt * : Transmission assembly
9 Bolt Ù : Non-reusable parts

NOTE
• For removal from vehicle, see ^ Gr 10.
• Check backlash of drive shaft gear 7 before disassembly.
• Do not remove needle bearing 3 from transfer input rear cover 4 unless it is faulty.

● Assembly sequence
Follow the disassembly sequence in reverse.

NOTE
Check backlash when assembling parts.

24-6
 24
Service standards Unit : mm {in.}
Location Maintenance item Standard value Limit Remedy
7, 11 Drive shaft gear and transfer idler gear backlash 0.08 to 0.22 {0.0031 to 0.0087} 0.50 {0.020} —

Ê Tightening torque Unit : N·m {lbf.ft, kgf·m}

Location Parts to be tightened Tightening torque Remarks
1 Bolt (Transfer input rear cover mounting) 44 {33, 4.5} —
5 Lock nut tightening torque 490±49 {360±36, 50±5} —
8 Bolt (Transfer assembly mounting) 44 {33, 4.5} —
9 Bolt (Transfer assembly mounting) 44 {33, 4.5} —
13 Bolt (Extension spacer mounting) 44 {33, 4.5} —

- Lubricant and/or sealant

Location Points of application Specified lubricant and/or sealant Quantity

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* Mounting surface of extension spacer transmission assembly THREEBOND 1215 As required
1 Thread area of pierce bolt THREEBOND 1104J As required
4 Mounting surface of transfer assembly transfer input rear cover THREEBOND 1215 As required
10 Lip area of oil seal and transfer assembly Wheel bearing grease As required
[NLGI No.2 (Li soap)]
14 Mounting surface of transfer assembly extension spacer THREEBOND 1215 As required

0 Special tools Unit : mm {in.}

Location Tool name and shape Part No. Application

ø25 {0.98}
ø32.5
{1.28}

3 Needle roller bearing MH061926 Installation of input rear cover needle

installer bearing
ø50
4 {0.16}
{1.97}
06396

50
{1.97}
5 Socket wrench 44490-44101 Removal and installation of transmission
main shaft lock nut

00069

184
ø55.5 {7.24}
{2.19}

10 Oil seal installer MH061924 Installation of oil seal

ø85
{3.35}
06398

24-7
REMOVAL AND INSTALLATION OF TRANSFER ASSEMBLY

0
3
◆ Service procedure
Installation of needle bearing
0 : Needle roller bearing installer

3 4

5
06399

Removal and installation of lock nut

0 : Socket wrench

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7
0
5
06400

11 F Installation of oil seal

Apply grease to lip area A of oil seal 10, and press-fit it.
10
0 : Oil seal installer

A 0
06401

24-8
 MEMO
24

24-9
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FRONT DRIVE

Ê3
Ù
Ê
-4
13
40

ÙÊ
33
11
31
30
28
27
- 26 36
Ê 35
20 Ê8

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14 *
Ê9 38 1Ê
37 -
22 * 3
7 Ê
34
6 29
-Ê5 19 39
20 -
Ù 16 17 21 Ù
Ê15 24
27 -
18
Ê
- -
Ù

27276

● Disassembly sequence
1 Bolt 14 Interlock ball 29 Synchronizer sleeve
2 Shift rail cover 15 Lock nut 30 Front drive shift fork
3 Bolt 16 O-ring 31 Snap ring
4 Transfer case side cover 17 Companion flange 32 Front drive shift rail
5 Screw plug 18 Bolt 33 Shift rail stopper
6 Poppet spring 19 Front drive shaft 34 Snap ring
7 Steel ball 20 Snap ring 35 Front drive hub
8 Transfer LOW switch 21 Bearing 36 Snap ring
^ Gr54 22 Dust cap 37 Bolt
9 Transfer four-wheel drive 23 Oil seal 38 Front drive case
switch ^ Gr54 24 Front drive case cover 39 Oil seal
10 Screw plug 25 Set bolt 40 Transfer assembly
11 Set bolt 26 Snap ring
12 HIGH/LOW shift rail 27 Retainer * : Dowel pin
13 HIGH/LOW shift fork 28 Spring Ù : Non-reusable parts

24-10
 24
NOTE
HIGH and LOW shift rail 12 cannot be disassembled unless front drive shift rail 32 is set to front drive ON.

● Assembly sequence
40→39→38→37→36→35→34→33
→ 25
32→31→30→28→27→26
29 ↑ →18→17→16→15→14→10
13→12→11
24→23→22→21→20→19 →9→8→7→6→5→4→3→2→1

Service standards Unit : mm {in.}

Location Maintenance item Standard value Limit Remedy
(Basic diameter in [ ])
6 Poppet spring free length 24.85 {0.98} 24.00 {0.94} Replace
12 Deflection of HIGH/LOW shift rail 0.02 {0.00079} or less 0.03 Correct
{0.0012} or replace

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12, 40 Clearance between HIGH/LOW shift rail [16 {0.63}] 0.05 to 0.09 0.2 Replace
and transfer assembly rail hole {0.0020 to 0.0035} {0.0079} faulty parts
13 Tilt of claw against HIGH/LOW shift fork hole 0.1 {0.0039} or less 0.2 {0.0079} Replace
13, 29 Clearance between HIGH/LOW shift fork 0.3 to 0.5 1.0 Replace
and synchronizer sleeve {0.012 to 0.020} {0.039} faulty parts
29, 30 Clearance between front drive shift fork 0.3 to 0.5 1.0 Replace
and synchronizer sleeve {0.012 to 0.020} {0.039} faulty parts
30 Tilt of claw against front drive shift fork hole 0.1 {0.0039} or less 0.2 Replace
{0.0079} faulty parts
32 Front drive shift rail deflection 0.02 {0.00079} or less 0.03 Correct
{0.0012} or replace
32, 40 Clearance between front drive shift rail [16 {0.63}] 0.05 to 0.09 0.2 Replace
and transfer assembly rail hole {0.0020 to 0.0035} {0.0079} faulty parts

Ê Tightening torque Unit : N·m {lbf.ft, kgf·m}

Location Parts to be tightened Tightening torque Remarks
1 Bolt (Shift rail cover mounting) 44 {33,4.5} —
3 Bolt (Transfer case side cover mounting) 24 {17, 2.4} —
5 Screw plug tightening 39 {29, 4} —
8 Transfer LOW switch tightening 34±4.9 {25±3.6, 3.5±0.5} —
9 Transfer four-wheel drive switch tightening 34±4.9 {25±3.6, 3.5±0.5} —

10 Screw plug tightening 39 {29, 4} —

11 Set bolt (Shift fork mounting) 29 {22, 3} Caulk at
three points
after
tightening
15 Lock nut tightening 295±49 {215±36, 30±5} —
18 Bolt (Front drive case cover mounting) 44 {33, 4.5} —
37 Bolt (Front drive case mounting) 44 {33, 4.5} —

24-11
FRONT DRIVE
- Lubricant and/or sealant
Location Points of application Specified lubricant and/or sealant Quantity
4 Mounting surface of transfer assembly transfer case side cover THREEBOND 1215 As required
5 Thread area of screw plug THREEBOND 1215 As required
10 Thread area of screw plug THREEBOND 1215 As required
18 Thread area of pierce bolt THREEBOND 1104J As required
23 Pack between lips of oil seal Wheel bearing grease [NLGI No.2 (Li soap)] As required
24 Mounting surface of front drive case front drive case cover THREEBOND 1215 As required
38 Mounting surface of transfer assembly front drive case THREEBOND 1215 As required
39 Lip area of oil seal Wheel bearing grease [NLGI No.2 (Li soap)] As required

0 Special tools Unit : mm {in.}

Location Tool name and shape Part No. Application

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20, 26, 34 Snap ring expander MH061268 Removal and installation of snap ring

01137

ø42
{1.65}
Bearing installer MB999104

ø52
23 {2.05} 05661 Installation of front drive case cover oil seal

Differential bearing inner MB999105

race installer adapter ø88
{3.46} ø50
{1.97} 05667

ø15.5 {0.61}

39 Oil seal installer MH061923 Installation of shift rail oil seal

ø35
{1.38} 19 {0.75} 06404

24-12
 24

GU
◆ Service procedure

Removal and installation of set bolt

Tighten shift fork mounting set bolt 11, 25 at specified torque, and stake
the thread area at three points using a punch.

H\
06405

Inspection of shift rail

If the measured value is higher than the limit, correct or replace shift rails
12, 32 12, 32.
NOTE

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To measure the deflection of shift rails 12, 32, turn them one full
revolution and read the dial gauge indicator. The deflection is
one half of the indicated value.

H\d
01127

Clearance between shift rail and transfer assembly

rail hole

40 Measure the outer diameter of shift rail 12, 32 and the inner diameter of
12, 32 transfer assembly hole 40. If the clearance is higher than the limit,
replace faulty parts.

IYZ
06406

Clearance between shift fork and synchronizer

sleeve
If the measured value is higher than the limit, replace faulty parts.
29

13, 30

06407

24-13
FRONT DRIVE

1
S Installation of oil seal
Apply grease to lip area A of oil seal 23, and press-fit it.
1 : Bearing installer
2 : Differential bearing inner race installer adapter
2
23

c
06409

Installation of oil seal

Apply grease to lip area A of oil seal 39 and press-fit it into transfer
40
A assembly 40.
0 : Oil seal installer

39 0

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06410

24-14
 MEMO
24

24-15
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IDLER GEAR AND REAR DRIVE

32 Ù 28 27 -
29
25Ê-Ù
31 Ù 30
34
32 29
26

9- 7Ê-Ù

Ê
10 11 1
12 Ù
13

4
- Ù
21
-
Ù
33

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Ê
-
33
Ê
-

19
Ù-
17
16
27278

● Disassembly sequence
1 Bolt 19 Rear drive shaft HIGH gear
2 Spring pin 20 Needle bearing
3 Speedometer gear 21 Synchronizer sleeve
4 O-ring 22 Needle bearing
5 Oil seal 23 Rear drive shaft LOW gear
6 Speedometer gear bushing 24 Needle bearing
7 Bolt 25 Bolt
8 Oil seal 26 Plate
9 Output rear cover 27 Idler rear cover
10 Speedometer worm 28 Shim
11 Key 29 O-ring
12 Snap ring 30 Transfer idler shaft
13 Bearing 31 Transfer idler gear
14 Thrust washer 32 Bearing
15 Rear drive shaft 33 Drain plug, inspection plug
16 Snap ring 34 Transfer case
17 Bearing
18 Thrust washer Ù : Non-reusable parts

24-16
 24
NOTE
• Check backlash and end play of gears before disassembly.
• Do not remove needle bearing 22 from rear drive shaft 15 unless it is faulty.

● Assembly sequence

31→32
34→33 →28→27→26→25
30→29 →17→16→11→10→22
15→21→24→23→14→13→12→20→19→18 →7
6→5→4→3→2
→1
9→8

NOTE
• Check backlash and end play when assembling parts.
• Check friction and rotation movements when assembling rotating parts.

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Service standards Unit : mm {in.}
Standard value
Location Maintenance item (Basic diameter in [ ]) Limit Remedy

— Starting torque of transfer idler gear 0 to 2 {0 to 1.45, 0 to 0.2} — Adjust shim

3, 6 Clearance between speedometer gear and [12] 0.04 to 0.09 0.15 Replace
speedometer gear bushing {[0.47] 0.0016 to 0.0035} {0.0059}
15, 19, 20 Play of rear drive shaft HIGH gear in diameter 0.02 to 0.06 0.12 Replace
direction after assembly {0.00079 to 0.0024} {0.0047} faulty parts
15, 23, 24 Play of rear drive shaft LOW gear in diameter 0.02 to 0.06 0.12 Replace
direction after assembly {0.00079 to 0.0024} {0.0047} faulty parts
19 End play of rear drive shaft HIGH gear 0.25 to 0.40 0.60 Replace
{0.0098 to 0.0016} {0.024} thrust washer
or gear
19, 31 Backlash between rear drive shaft HIGH gear 0.08 to 0.22 0.50 Replace
and transfer idler gear {0.0031 to 0.0087} {0.020}
21 Clearance between synchronizer sleeve groove 0.3 to 0.5 1.0 Replace
and HIGH/LOW shift fork {0.012 to 0.020} {0.039} faulty parts
23 End play of rear drive shaft LOW gear 0.25 to 0.40 0.60 Replace
{0.0098 to 0.016} {0.024} thrust washer
or gear
23, 31 Backlash between rear drive shaft LOW gear 0.08 to 0.24 0.50 Replace
and transfer idler gear {0.0031 to 0.0094} {0.020}

Ê Tightening torque Unit : N·m {lbf.ft, kgf·m}

Location Parts to be tightened Tightening torque Remarks
1 Bolt (Speedometer gear bushing mounting) 24 {17, 2.4} —
7 Bolt (Output rear cover mounting) 44 {33, 4.5} —
25 Bolt (Plate and idler rear cover mounting) 44 {33, 4.5} —
33 Drain plug and inspection plug tightening 69±15 {51±11, 7.0±1.5} —

24-17
IDLER GEAR AND REAR DRIVE
- Lublicant and/or sealant
Location Points of application Specified lublicant and/or sealant Quantity
3 Friction surfaces between speedometer gear and speedometer Molybdenum disulfide grease As required
gear bushing
5 Lip area of oil seal Wheel bearing grease [NLGI No.2 (Li soap)] As required
7 Thread area of bolt THREEBOND 1104J As required
8 Pack between lips of oil seal Wheel bearing grease [NLGI No.2 (Li soap)] As required
9 Mounting surface of transfer case output rear cover THREEBOND 1215 As required
25 Thread area of bolt THREEBOND 1104J As required
27 Mounting surface of transfer case idler rear cover THREEBOND 1215 As required
33 Thread area of drain plug and inspection plug THREEBOND 1105D As required

0 Special tools Unit : mm {in.}

Location Tool name and shape Part No. Application

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16.5
{0.65}

8 Oil seal installer MH062691 Installation of output rear cover oil seal

06252

12 Snap ring expander MH061268 Removal and installation of snap rings

01137

ø40
{1.57}

22 Needle roller bearing MH061927 Installation of rear drive shaft needle

installer bearing
ø13
ø18.5 {0.51} 28 {1.10}
{0.73} 15 {0.59} 06413

24-18
 24
◆ Service procedure
Inspection before service
● Starting torque of transfer idler gear
28 31
• Disassemble parts, and measure the torque with push gauge A
A
leaving only transfer idler gear 31 in transfer case.
If the value deviates from the standard value, adjust it using shim
28.
• On assembly, also check that starting torque is within the standard
value range using the same method.
• Shim 28 is available in four thicknesses : 0.01 mm {0.00039 in.},
0.02 mm {0.00079 in.}, 0.03 mm {0.0012 in.}, 0.06 mm {0.0024 in.}.

2
07633

2 Driving-in spring pin

Drive spring pin 2 into speedometer gear bushing 6 with the opening in
the opposite direction to speedometer gear 3.

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3
6

36
03576

Clearance between speedometer gear and speedometer

gear bushing
3
If the clearance is higher than the limit, replace the faulty parts.

5
03577

Installation of oil seal

B Apply grease to lip area A of the inner rim of the oil seal, and press-fit oil
seal evenly into speedometer gear bushing 6 in the direction as illus-
trated using bar B (approximately ø15 mm {0.59 in.}).

A 5
6
03578

24-19
IDLER GEAR AND REAR DRIVE
6 Installation of speedometer gear bushing
Due to its eccentric center arrangement, speedometer gear bushing 6
6 allows replacement of speedometer gear 3 with gears having a different
number of teeth by changing only the installation direction, the worm
gear does not have to be changed.
M
When installing the bushing, align the stamped number, identical to the
number of speedometer gear teeth, with alignment mark M of output rear
cover 9.
The number of speedometer gear teeth can be identified by the identifi-
cation marks stamped on N or P.

3 P N Identification mark and number of speedometer gear teeth

Identification
mark A B C D L E F G H I J K

Number of
teeth 15 16 17 18 19 20 21 22 23 24 25 26

Gear ratio 3.0 3.2 3.4 3.6 3.8 4.0 4.2 4.4 4.6 4.8 5.0 5.2

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8
06416

Installation of oil seal

Apply grease to lip area A of oil seal 8 and press-fit it into output rear
cover 9.

0 8

JN
06419

Installation of thrust washer

Install thrust washer 14, 18 with oil groove A facing gear side.

A 14, 18

06418

24-20
 24
KNPST Play of rear drive shaft gear in diameter
direction after assembly
If the measured value is higher than the limit, replace faulty parts.
NOTE
When replacing needle bearing 20, 24, use bearings from the
same color package.

R
01149

Installation of needle bearing

0 : Needle roller bearing installer
0 22

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06420

24-21
TRANSFER CONTROL
Control Cable < Removal from the transfer side >
● Work before removal
*b Ê Õ P24-22
Ê
1 3 ● Removal sequence
2Ê
1 Bolt
4
2 Nut
3 Nut
4 HIGH/LOW control cable
5 2H/4H control cable
6 Shift rail cover

*a : Transfer body
*b : HIGH/LOW shift rail
*c : Front drive shift rail

*a *c 1 3
6 2 5 ● Installation sequence
Ê

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Ê
Ê Follow the removal sequence in reverse.
27279

Ê Tightening torque Unit : N·m {lbf.ft, kgf·m}

Location Parts to be tightened Tightening torque Remarks
1 Bolt (Shift rail cover mounting) 44 {33, 4.5} —
2, 3 Nut (HIGH/LOW and 2H/4H control cable mounting) 44 to 59 {33 to 43, 4.5 to 6.0} —

◆ Service procedure
● Work before removal
A When removing, move shift lever knob A of the transfer control bar to
the position 4H.

27280

24-22
 24
1
45
[Removal]
HIGH/LOW, 2H/4H Control Cable

• Remove bolt 1 securing shift rail cover 6.

6
1
27281

• Remove shift rail cover 6, and then remove inner cable A of HIGH/
*b, *c LOW and 2H/4H control cables 4 and 5, from HIGH/LOW shift rail *b,
*b, *c 3 2 A 3 2
and front drive shift rail *c. Loosen nuts 2 and 3 to their end of their
threads.

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A 6 4, 5 6 4, 5
27282

• Remove HIGH/LOW and 2H/4H control cables 4 and 5 from shift rail
cover 6.
4

5
6 27283

B [Installation]
*b • Position HIGH/LOW shift rail *b and front drive shift rail *c as shown.
15 mm {0.59 in.} B : Transfer end face

8 mm {0.31 in.}

*c 27284

• Adjust nuts 2 and 3 to the end of the thread to align the end of HIGH/
3 2
LOW and 2H/4H control cables 4 and 5 as shown.

8±2 mm
{0.31±0.079 in.}
4, 5
27285

24-23
TRANSFER CONTROL
•Screw nut 3 into shift rail cover 6 and tighten it to the specified torque.
2 mm
{0.079 in.}
3
C CAUTION–
• Ensure that the HIGH/LOW and four-wheel / two-wheel drive
control cables are not positioned incorrectly.
The cable with the white line C is for HIGH/LOW.
• After installation, the end of nut 3 should be located 2
mm{0.079 in.} from the front face of shift rail cover 6.

6 3
27286

2 mm • Tighten the nut with its specified torque and lock it with nut 3. Then
*b, *c {0.079 in.} *b, *c slide the shift rail cover 6 and install the inner cable A to HIGH/LOW
shift rail *b and front drive shift rail *c.

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6 2 A 6 2
A
27287

1 • Tighten shift rail cover 6 installation bolt 1 at the specified torque.

10±2 mm
{0.39±0.079 in.}

10±2 mm
6 {0.39±0.079 in.}
1 27288

24-24
 MEMO
24

24-25
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TRANSFER CONTROL
Control cable < Removal from the transfer control cable side >
● Removal Sequence
1 Nut
2 Bolt
3 Lock pin
4 Nut
5 HIGH/LOW control cable
6 Nut
7 2H/4H control cable
Ê
1
● Installation sequence
Follow the removal sequence in reverse.
3

Ê2

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6Ê

6Ê

Ê4

Ê4
7

27289

Ê Tightening torque Unit : N·m {lbf.ft, kgf·m}

Location Parts to be tightened Tightening torque Remarks
1 Nut (HIGH/LOW control cable mounting) 3.9 to 5.9 {2.9 to 4.3, 0.4 to 0.6} —
2 Bolt (2H/4H control cable mounting) 3.9 to 5.9 {2.9 to 4.3, 0.4 to 0.6} —
4, 6 Nut (HIGH/LOW control cable and 2H/4H control 44 to 59 {33 to 43, 4.5 to 6.0} —
cable mounting)

24-26
 24
◆ Service procedure
● Adjustment after installation
A • Position shift lever A on position 4H.

27280

• Adjust the distance between the center of the steering wheel and
245 mm {9.65 in.}
center of the shift lever knob A using the nut 6.

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27290

• Adjust nut 4 until the distance between shift lever A and the front face
6.5 mm of inner panel B is equal to distance illustrated.
{0.26 in.}
A

27291

24-27
TRANSFER CONTROL
Transfer Control Level

Ê 17

22

18
21
1

Ê2 5
-8

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Ê 6-
7

- 13
14
9 15

16

19 - 14

14
20 -
14 12 Ê
-
11
10 Ê
27292

● Disassembly sequence
1 Pin 9 Spring 17 Shift lever knob
2 Nut 10 Bolt 18 Change lever assembly
3 Support holder 11 Conical spring 19 Bracket
4 Spring 12 Nut 20 Bracket
5 Ball supporter 13 Collar 21 Stopper
6 Steel ball 14 Bushing 22 Lever bracket
7 Bolt 15 Cross sleeve
8 Detent plate 16 Conical spring

CAUTION–
• When removing pin 1, be careful that spring 4 does not fly out.
• When removing support holder 3, ensure that steel ball 6 is not dropped.

24-28
 24
● Assembly sequence

15→14→13→11
↓
22→21→20→19 →10→12→8→7→6→5→4→3→2→1
↑
18→17→16→9 

Service standards Unit : mm {in.}

Location Maintenance item Standard value Limit Remedy
9 Spring load (installation 133 {5.24}) 46 N {10 lbf, 4.7 kgf} 41 N Replace
{9 lbf,4.2 kgf}

Ê Tightening torque Unit : N·m {lbf.ft, kgf·m}

Location Parts to be tightened Tightening torque Remarks
2 Nut (Support holder mounting) 3.9 to 5.9 {2.9 to 4.3, 0.4 to 0.6} —
7 Bolt (Detent plate mounting) 3.9 to 5.9 {2.9 to 4.3, 0.4 to 0.6} —

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10 Bolt (Cross sleeve mounting) 8.8 to 13.7 {6.5 to 10.0, 0.9 to 1.4} —
12 Nut (Change lever assembly mounting) 8.8 to 13.7 {6.5 to 10.1, 0.9 to 1.4} —
17 Shift lever knob mounting 5.9±1.5 {4.3±1.08, 0.6±0.15} —

- Lubricant
Location Points of application Specified lubricant Quantity
6 Apply grease all over the steel ball Multipurpose type grease [NLGI No.2 (Li soap)] As required
8 Apply grease all over detent plate Multipurpose type grease [NLGI No.2 (Li soap)] As required
14 Grease inside surface of bushing Multipurpose type grease [NLGI No.2 (Li soap)] As required

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