92Rocky-TR-Transmission_and_Transfer-Part1
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PART 1 - PART 2 - PART 3 - PART 4
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DAIHATSU
Rocky
TRANSMISSION & TRANSFER
TRANSFER TR- 2 CONTROL LEVER-RELATED TR-35 "_ COMPONENTS TR-35 REMOVAL TR-36 INSPECTION TR-36 INSTALLATION TR-36 DISASSEMBLY OF SHIFT & SELECT
COMPONENTS TR- 2 TRANSFER DISASSEIVIBLY TR- 4 DISASSEIVIBLY OF TRANSFER
OUTPUT FRONT SHAFT TR-13 DISASSEIVIBLY OF TRANSFER
OUTPUT REAR SHAFT TR-13 INSPECTION (FRONT DRIVE CHAIN) TR-15 INSPECTION (TRANSFER I-IIGI-I &
LOW CLUTCH SLEEVE) TR-16 ASSEMBLY (TRANSFER OUTPUT
FRONT SHAFT BEARING) TR-20 ASSEMBLY TR-22
ASSEMBLY TR-38
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TRANSMISSION & TRANSFER
G) Transfer high & low clutch sleeve Transfer output rear shaft C53) Needle roller bearing Transfer low speed output gear © Transfer output gear thrust washer © Radial ball bearing (D Front drive clutch hub (Q Transfer output shaft spacer No. 2
© Transfer froht drive geér beariffg inner race
Needie roller bearing “E” ring Transfer high & low shift fork “E” ring Bolt Gasket Spring Ball Transfer high & low shift fork shaft ® Radial ball bearing Transfer counter gear Sub-gear No. 2 Washer plate Conical spring washer Snap ring Radial ball bearing Transfer front drive gear sleeve Transfer front drive chain ® Transfer front drive gear Transfer output gear thrust washer ® Radial ball bearing Lock nut Q2) Bali Speedometer drive gear G-D Snap ring Transmission position detecting switch Q6) Gasket
Roller Roller Spring Bolt Gasket Ball Transfer front drive shift fork shaft "E" ring Spring “E” ring Transfer front drive shift fork Radiat ball bearing Transfer output front shaft Radial ball bearing Extension housing dust deflector Oi! seal Tight plug Transfer front case subassembly Transfer oil supply pipe Transfer case gasket Transfer rear case Lock nut Bearing Transfer low speed input gear Sub-gear No. 1 Washer plate Conical spring washer Snap ring Radial ball bearing Oil seal Transmission output shaft Exhaust pipe support bracket Engine hanger Transfer adapter subassembly Straight pin Hexagon bolt
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TRANSMISSION & TRANSFER
TRANSFER DISASSEMBLY
i (As for the removal of transmission assembly with transfer, See page MT-1610 MT-20.) y
2. Place a Wooden p\ate(s) or any other suitable materials on
retainer subassembly by removing the hexagon bolt.
4. Remove the control shaft with instailed the shift lever
5. Remove the breather hose by detaching a clip. / /
6. Remove the transfer shift lever retainer and gasket by
removing the four bolts. (As for the disassembly/assembly and inspection for the removed parts, see page TR-36.)
TR-4
W
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TRANSMISSION & TRANSFER
Remove the speedometer sleeve lock plate by removing the bolt.
Remove the speedometer sleeve, using the standard tool of flat driver arrow to remove the speedometer sleeve.
Removal of transfer output shaft bearing retainer
(2) Remove the transfer eutput shaft bearing retainer by tapping the both right and left ribs section, using the wooden bar with plastic hammer lightly. (3) Remove the gasket. NOTE: o Never reuse the removed gasket.
Remove the control shaft lower No. 1 bracket with installed the shift & select shaft and control shaft by removing the two he-xagon boits and the bolt.
ki
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TRANSMISSION & TRANSFER
gear and ball. NOTE: v Never reuse the removed snap ring
11. Detach the snap ring. Remove the speedometer driven
12. Remove the transmission case cover subassembly by
removing the seven bolts and the reamer bolt
13. Interlock the 1st gear and the 3rd gear.
14. Raise the lock section of the lock nut.
15. Remove the lock nut from the transfer output rear shaft,
using the following SST.
SST: 09326-20022-000
16. Remove the torsion bar spring, using the standard tool of
flat driver.
C)
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TRANSMISSION & TRANSFER
Drive out the slotted pin of the transfer front drive shift head. Remove the transfer front drive shift head. (As for the inspection for the removed parts, see page 0 Tn_19.)
Remove the transfer fork shaft pin. (As for the inspection for the removed parts, see page TR-19.)
Remove the “E” ring. Remove the transfer high & iow shift /7,/ f
head.
Drive out the slotted pin ofthe transfer front drive shift head V/ ,___ No. 2. Remove the transfer front drive shift head No. 2. Kao " (As for the inspection for the removed parts, see page A A 9 . .l TR-19,)
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TRANSMISSION & TRANSFER
22. Remove the transfer rear case by removing the eight bolts.
23. Remove the transfer rear case by Iightiy tapping the ribs
24. Remove the gasket and transfer oil supply pipe.
25. Remove the bearing, using the following SSTS.
(As for the inspection for the removed parts, see page
SST: 09950-20017-000 09956-00010-000
Of
It
09956-00010-000
09950-2001 7-OOO
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TRANSMISSION & TRANSFER
26. Remove the transfer output gear thrust washer. 27. Remove the transfer front drive chain and transfer output
gear together with the transfer output front shaft. (As for the inspection for the removed parts, see page TR-15.) NOTE: Lightly tapping the transfer front shaft A with a plastic
hammer. - Pull out the transfer output rear shaft and transfer front shaft with installed the transfer front drive chain toward you B.
28. Remove the needle roHer bearing and transfer front drive
gear bearing inner race.
(As for the inspection for the removed parts, see page TR-19.)
29. Remove the transfer output gear thrust washer.
30. Remove the transmission position detect switch and gasket.
NOTE:
o Never reuse the removed gasket.
31. Remove the roller, using the standard tool of magnet hand.
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TRANSMISSION & TRANSFER
. Remove the lock bolt of the transfer front drive shift fork ,
~ Never reuse the removed gasket.
. Remove the lock bolt of the transfer high & Iovv shift fork
_ Remove the compression spring and ball, using the stand- E
ard tool of magnet hand.
6. Turn the transfer front drive shift fork shaft 180 degree and
Transfer front drive gear sleeve Transfer front drive shift fork Transfer front drive shift fork shaft Needle roller bearing Transfer front drive gear bearing inner race
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then, remove the following parts in a set. o Trnnsfnr frnnr dri _ o Transfer frnnr drive fnrk
TR-10
