Shift Link Assembly: Installation

Clean the mating surface of the transmission cover and transfer case.
Replace the seal ring with a new part, and install the shift accent plunger and the check ball spring.
Tightening torque:

25 N.m (2.5kgf-m, 18.4ft-lb)

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Using the ST, install a new needle bearing.
CAUTION: If the press-fit depth exceeds the service limit, replace with a new needle bearing.

Special tool:

ST1: 18763AA000 COMPRESSOR SHAFT

ST2: 498277200 STOPPER SET

Specification:

A: 8.5±0.2 mm (0.33±0.01in) from the end of transfer case

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B: 0.2±0.2 mm (0.01±0.01in) from the end of transfer case

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Set the ST1, ST2 and transfer case to the press.
NOTE:
- Set the ST2 under the ST1.
- Set the transfer case so that the hole for shifter arm is positioned vertically.
Special tool:

ST1: 498267300 CYLINDER HEAD TABLE

ST2: 498267200 CYLINDER HEAD TABLE

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Using the ST, install a new roller bearing.
CAUTION: If the press-fit depth exceeds the service limit, replace with a new bearing.

NOTE: Gradually perform the press-fit operation while measuring the press-fit depth.

Special tool:

ST: 899864100 REMOVER

Specification:

A: 5.1±0.2 mm (0.20±0.01in) from the finished surface of transfer case

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Flip over the transfer case, and set an iron plate between transfer case and ST.
NOTE:
- Insert the steel plate, which is thicker than the exposed length of the transfer case knock pin, between the ST and transfer case.
- Set the parts while taking care that the transfer case knock pin and the roller bearing do not ride over the iron plate.
Using the ST, install a new roller bearing.
CAUTION: If the press-fit depth exceeds the service limit, replace with a new bearing.

NOTE: Gradually perform the press-fit operation while measuring the press-fit depth.

Special tool:

ST: 899864100 REMOVER

Specification:

A: 0±0.2 mm (0±0.01in) from the end of transfer case

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Using the ST, install a new oil seal.
NOTE:
- The illustration shows the oil seal of selector lever COMPL. Perform the same procedures for installing the oil seal of shifter arm No. 2.
- Apply transmission gear oil to the oil seal lips.
Special tool:

ST: 18657AA000 INSTALLER

Specification:

1±0.2 mm (0.04±0.01in) from the end of transfer case

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Insert the shifter arm and fix with a new straight pin.
Special tool:

ST: 398791700 REMOVER

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Install the shifter arm No. 2, adjusting washers and thrust bearing.
CAUTION: Be careful not to damage the oil seal.

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Replace the gasket with a new part, and install the shifter arm collar and neutral set spring.
Tightening torque:

6.4N.m (0.7kgf-m, 4.7ft-lb)

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Install the selector arm No. 2.

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Insert the selector lever COMPL and fix with a new straight pin.
CAUTION: Be careful not to damage the oil seal.

Special tool:

ST: 398791700 REMOVER

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Insert a new straight pin.

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Install the center differential and transfer driven gear as a unit.
Install the transfer case and the extension case assembly. Ref. to MANUAL TRANSMISSION AND DIFFERENTIAL (6MT)>Transfer Case and Extension Case Assembly>INSTALLATION .
Apply liquid gasket seamlessly.
Liquid gasket:

THREE BOND 1215B or equivalent

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Install the transmission cover.
Tightening torque:

25 N.m (2.5kgf-m, 18.4ft-lb)

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Install the back-up light switch and the neutral position switch. Ref. to MANUAL TRANSMISSION AND DIFFERENTIAL (6MT)>Switches and Harness>INSTALLATION .
Install the manual transmission assembly to the vehicle. Ref. to MANUAL TRANSMISSION AND DIFFERENTIAL (6MT)>Manual Transmission Assembly>INSTALLATION .