4WD Output Disassembly and Assembly (continued)
21. Measure ID of pilot hole. If not within
specifications, replace 4WD output shaft.
22. Inspect sleeve on 4WD output shaft (N) for wear.
Re-place, as necessary.
23. Inspect splines on 4WD output shaft (N) and shift collar
(Q) for damage. Replace as required. (Fig. 52)
24. Inspect groove in shift collar (Q) for scoring or
damage. Replace as required.
Specifications for 4WD Output Shaft:
• OD at Bearing . . . . . . 24.98 - 25.0 mm (0.983 - 0.984 in.)
• ID Pilot Hole . . . . . . . 17.0 - 17.02 mm (0.669 - 0.670 in.)
25. Measure shaft bore in 4WD cover. If not in
specifications, replace housing.
26. Measure OD of shaft in bearing area. If not in
specifica-tions, replace shaft.
Specifications:
• Shaft OD . . . . . . . . . . . 16.93 - 17 mm (0.667 - 0.669 in.)
• 4WD Cover Shaft Bore ID 17 - 17.043 mm
(0.669 - 0.671 in.)
Assembly and Installation:
Assembly and installation of the 4WD output assembly is
car-ried out in reverse order of disassembly and removal.
Replace the gasket (AE, see fig. 52), and gasket (AF, only if
4WD gear case was removed) or use a thin bead of silicone
sealant between motor case assembly and 4WD gear case.
Also, between 4WD gear case and 4WD cover.
Refill transaxle w/approximately 7.8L (8.2 qt) for 4WD
and 9.0L (9.5 qt) for 4WD w/rear PTO. Use ATF Type
F and fill to crosshatched area of dipstick.
Tighten cap screws to specification.
Torque Specification:
• Cap Screws. . . . . . . . . . . . 16 - 22 N•m (144 - 192 lb-in.)
4WD Output Disassembly
A - 4WD Front Cover
B - 4WD Gear Case
C - Shift Arm 4WD
D - Seal
E - Bearing
F - Bolt
G - Shaft Shift 4WD
H - Bolt
I - Bolt (12 mm)
J - Gasket
K - O-ring
L - Spring Pin
M - Spring Pin
N - Shaft Front Drive
O - Arm Shift 4WD
P - Block Shift Bearing
Q - Collar Front Shift
R - Gear 4WD
S - Shaft 4WD
T - Collar
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