1. TRANSMISSION CASE (1) | Air breather hose | (7) | Harness clip | | (2) | Clamp | (8) | Transmission radio ground cord | Tightening torque: N·m (kgf-m, ft-lb) | (3) | Hose clamp | (9) | Gasket | T1: | 18 (1.8, 13.3) | (4) | Harness bracket | (10) | Drain plug | T2: | 44 (4.5, 32.5) (aluminum gasket, silver) | (5) | Air breather hose bracket | (11) | Transmission case ASSY | | 70 (7.1, 51.6) (copper gasket, brown) | (6) | Select bracket | (12) | Oil level gauge | | 70 (7.1, 51.6) (metal gasket, black) |
Transmission case tightening torque | Bolt No. | Bolt size mm | Tightening torque: N·m (kgf-m, ft-lb) | (5) — (15) | 8 | 25 (2.5, 18.4) | (1) — (4) (16), (17) | 10 | 40 (4.1, 29.5) |
2. DRIVE PINION SHAFT ASSEMBLY (1) | Drive pinion shaft | (15) | 1st-2nd shifting insert | (29) | Lock nut | (2) | Roller bearing | (16) | 1st-2nd coupling sleeve | (30) | Adjusting washer | (3) | Washer | (17) | 2nd outer baulk ring | (31) | Thrust bearing | (4) | Thrust bearing | (18) | 2nd synchro cone | (32) | Differential bevel gear sleeve | (5) | Needle bearing | (19) | 2nd inner baulk ring | (33) | Washer | (6) | Driven shaft | (20) | 2nd driven gear | (34) | Lock washer | (7) | Key | (21) | 2nd driven gear bushing | (35) | Lock nut | (8) | Drive pinion collar | (22) | 3rd-4th driven gear | | | (9) | Needle bearing | (23) | Drive pinion shim | Tightening torque: N·m (kgf-m, ft-lb) | (10) | 1st driven gear | (24) | Double ball bearing | T1: | 30 (3.1, 22.1) | (11) | 1st inner baulk ring | (25) | 5th driven gear | T2: | 126 (12.8, 92.9) | (12) | 1st synchro cone | (26) | Drive pinion spacer | T3: | 440 (44.9, 324.5) | (13) | 1st outer baulk ring | (27) | 6th driven gear | | | (14) | 1st-2nd synchronizer hub | (28) | Ball bearing | | |
3. MAIN SHAFT ASSY (1) | Oil seal | (13) | 4th drive gear | (25) | 5th-6th coupling sleeve | (2) | Needle bearing | (14) | 4th needle bearing race | (26) | 6th baulk ring | (3) | Main shaft | (15) | 4th needle bearing | (27) | 6th drive gear | (4) | 3rd needle bearing | (16) | 4th gear thrust washer | (28) | 6th needle bearing race | (5) | 3rd drive gear | (17) | Double taper roller bearing | (29) | 6th needle bearing | (6) | 3rd inner baulk ring | (18) | 5th needle bearing race | (30) | Ball bearing | (7) | 3rd synchro cone | (19) | 5th needle bearing | (31) | Lock washer | (8) | 3rd outer baulk ring | (20) | Main shaft rear plate | (32) | Lock nut | (9) | 3rd-4th coupling sleeve | (21) | 5th drive gear | | | (10) | 3rd-4th synchronizer hub | (22) | 5th baulk ring | Tightening torque: N·m (kgf-m, ft-lb) | (11) | 3rd-4th shifting insert | (23) | 5th-6th synchronizer hub | T: | 160 (16.3, 118.0) | (12) | 4th baulk ring | (24) | 5th-6th shifting insert | | |
4. REVERSE IDLER GEAR ASSY (1) | Reverse idler gear shaft | (9) | Reverse idler gear | (17) | Gasket | (2) | Reverse idler gear washer | (10) | Reverse idler gear collar | (18) | Reverse idler spring | (3) | Thrust bearing | (11) | Needle bearing | (19) | Reverse idler sub gear | (4) | Needle bearing | (12) | Thrust bearing | (20) | Friction plate | (5) | Reverse idler gear No. 2 | (13) | Reverse idler gear washer | (21) | Snap ring | (6) | Reverse coupling sleeve | (14) | Oil case guide | | | (7) | Reverse baulk ring | (15) | Reverse idler gear bushing | Tightening torque: N·m (kgf-m, ft-lb) | (8) | Reverse shifting insert | (16) | Snap ring | T: | 25 (2.5, 18.4) |
5. SHIFTER FORK AND SHIFTER ROD (1) | Shifter arm | (8) | 3rd-4th shifter fork | (15) | Checking ball plug | (2) | Selector arm | (9) | 3rd-4th fork rod | (16) | Checking ball spring | (3) | Straight pin | (10) | 1st-2nd shifter fork | (17) | Check ball | (4) | Reverse shifter fork | (11) | 1st-2nd fork rod | (18) | Gasket | (5) | Reverse fork rod | (12) | Interlock plunger | | (6) | 5th-6th shifter fork | (13) | Interlock plunger | Tightening torque: N·m (kgf-m, ft-lb) | (7) | 5th-6th fork rod | (14) | Interlock plunger | T: | 20 (2.0, 14.8) |
6. TRANSFER CASE AND EXTENSION (1) | Shifter arm | (15) | Adjusting washer | (29) | Snap ring | (2) | Interlock plate | (16) | Transfer drive gear | | | (3) | Gasket | (17) | Ball bearing | Tightening torque: N·m (kgf-m, ft-lb) | (4) | Transfer case | (18) | Snap ring | T1: | 15 (1.5, 11.1) | (5) | Transmission hanger | (19) | Extension case | T2: | 18 (1.8, 13.3) | (6) | Gasket | (20) | Bushing | T3: | 20 (2.0, 14.8) | (7) | Neutral position switch | (21) | Oil seal | T4: | 24.5 (2.5, 18.1) | (8) | Back-up light switch | (22) | Dust cover | T5: | 26 (2.7, 19.2) | (9) | Taper roller bearing (transfer case side) | (23) | Dust cover (OUTBACK model) | T6: | 32.3 (3.3, 23.8) | (10) | Transfer driven gear | (24) | Shift bracket | T7: | 40 (4.1, 29.5) | (11) | Taper roller bearing (extension case side) | (25) | Oil guide | | | (12) | Adjusting washer | (26) | Gasket | | | (13) | Ball bearing | (27) | Precoat bolt | | | (14) | Center differential | (28) | Needle bearing | | |
7. SHIFT LINK ASSEMBLY (1) | Selector lever COMPL | (11) | Thrust bearing | (21) | Seal ring | (2) | Selector arm No. 2 | (12) | Oil seal | (22) | Needle bearing | (3) | Shifter arm collar | (13) | Straight pin | (23) | Roller bearing | (4) | Neutral set spring | (14) | Transfer case | (24) | Precoat bolt | (5) | Straight pin | (15) | Gasket | | (6) | Selector arm | (16) | Checking ball spring | Tightening torque: N·m (kgf-m, ft-lb) | (7) | Shifter arm | (17) | Shift accent plunger | T1: | 6.4 (0.7, 4.7) | (8) | Shift lever COMPL | (18) | Seal bolt | T2: | 20 (2.0, 14.8) | (9) | Shifter arm No. 2 | (19) | Interlock plate | T3: | 25 (2.5, 18.4) | (10) | Adjusting washer | (20) | Transmission cover | | |
8. FRONT DIFFERENTIAL (1) | Drive pinion shaft | (7) | Differential bevel pinion | (13) | Retainer lock plate | (2) | Hypoid driven gear | (8) | Taper roller bearing | (14) | Front oil guide | (3) | Pinion shaft | (9) | Differential case | | | (4) | Straight pin | (10) | Oil seal | Tightening torque: N·m (kgf-m, ft-lb) | (5) | Adjusting washer | (11) | Differential side retainer | T1: | 25 (2.5, 18.4) | (6) | Differential bevel gear | (12) | O-ring | T2: | 62 (6.3, 45.7) |
9. TRANSMISSION MOUNTING (1) | Spacer | (7) | Center crossmember | (13) | Spacer | (2) | Lower cushion rubber | (8) | Front crossmember | | | (3) | Front plate | (9) | Rear cushion rubber | Tightening torque: N·m (kgf-m, ft-lb) | (4) | Transmission cushion rubber | (10) | Rear plate | T1: | 35 (3.6, 25.8) | (5) | Rear crossmember | (11) | Transmission main mounting bracket (RH) | T2: | 45 (4.6, 33.2) | (6) | Upper cushion rubber | (12) | Transmission main mounting bracket (LH) | T3: | 70 (7.1, 51.6) | | | | | | T4: | 75 (7.6, 55.3) | | | | | | T5: | 140 (14.3, 103.3) |
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Preparation tool
