Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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Disassembly (Ram-50) 1) Remove both 4WD indicator switches and steel balls. Remove speedometer gear assembly. Remove output shaft cover, gasket, wave spring and spacer. See Fig. 3. Remove rear cover, rear cover gasket and spacer from chain cover. Drive roll pin out of high-low shift fork. 2) Remove 2 seal plugs. Remove 2 poppet springs and steel balls. Shift transfer case to “4WD” and pull high-low shift rail out, in rear cover direction. Remove interlock plunger. Remove pulse generator (if equipped), front output shaft cover and pulse rotor (if equipped). Remove snap ring from rear bearing on output shaft. Remove chain cover, oil guide and side cover. Remove countershaft locking plate. Remove countershaft. 3) Remove countergear, 2 thrust washers, 2 needle bearings and spacer through side cover opening. Remove snap ring, spring retainers and spring from 2WD-4WD shift rail. Remove front output shaft, rear output shaft and chain as assembly. 4) Remove 2WD-4WD shift fork and distance piece. Drive out 2WD-4WD shift rail spring pin. Remove 2WD-4WD shift rail and lug. Remove high-low shift fork and high-low synchronizer sleeve. Remove needle bearing and snap ring from input gear. Remove input gear assembly. 5) If either control shaft or input gear oil seals are to be replaced, drive out roll pin from transmission control change shifter. Separate transfer case from adapter. See Fig. 3. Disassembly (Montero) 1) Remove dynamic damper, 5 detection switches and 3 steel balls. Remove poppet plug, spring and steel ball. Remove speedometer gear assembly. Remove output shaft rear cover, spacers, dust seal guard and oil seals. Front output shaft cover, wave spring and spacer (if equipped). 2) Remove high-low shift rail plug and high-low shift fork spring pin. Shift transfer case to “4WD”. Remove rear cover and high- low shift rail. Remove interlock plunger. Remove rear output shaft (viscous coupling) assembly and center differential assembly. Remove 2WD-4WD synchronizer assembly, chain and front output shaft from transmission as a unit. With White paint make match marks in grooves of 2WD-4WD synchronizer in 3 places. With White paint make match marks on spline projections of 2WD-4WD synchronizer sleeve in 3 places. Refer to match marks during reassembly. 3) Remove snap ring, spring seat, spring, 2WD-4WD shift fork and 2WD-4WD synchronizer sleeve. Remove differential lock hub, oil dam cover and bearing retainer. Remove side cover and gasket. Remove transfer counter gear shaft, transfer counter gear, thrust washer, needle bearings and spacer. Remove transfer drive shaft assembly. Remove high-low shift fork assembly and clutch sleeve. Remove transfer input gear assembly. 4) Remove 2WD-4WD shift lug spring pin, spring, spring retainer 2WD-4WD shift lug and shift rail. Remove input gear oil seal, baffle plate, dust seal guard and front output shaft oil seal. See Fig. 4.

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CAUTION: The hub bearing could be damaged if it is subjected to the vehicle weight, such as when moving the vehicle with the drive shaft removed. Therefore, if it is absolutely necessary to place the vehicle weight on the hub bearing, first support it with Special Service Tool (SST) 09608 – 16042 (09608 – 02021, 09608 – 02041 PROCEDURE 1. Remove front wheel and front fender apron seal. [Torque: 103 Nm (76 ft. lbs.)] 2. Remove drive shaft lock nut. a. Remove the cotter pin and lock cap. b. With applying brakes, remove the nut. [Torque: 294 Nm (217 ft. lbs.)] See TSB DL001-98, 3-6-98. 3. Drain ATF. 4. Disconnect tie rod end from steering knuckle. 5. Disconnect lower ball joint from lower suspension arm. 6. Disconnect drive shaft from axle hub. a. Using a plastic hammer, disconnect drive shaft from axle hub. CAUTION: Cover the drive shaft boot with cloth to protect it from damage. b. Push the front axle hub toward the outside of the vehicle, and separate the drive shaft from the axle hub. 7. Remove LH drive shaft. a. Using a brass bar and hammer, remove the drive shaft. Installation Note: – Coat gear oil to the inboard joint shaft and differential case sliding surface. – Before installing the drive shaft, set the snap ring opening side facing downward. – Whether or not the inboard joint shaft is making contact with the pinion shaft can be known by the sound or feeling when driving it in. – After installation: – check that there is 2 – 3 mm (0.08 – 0.12 inch). of play in the axial direction. – check that the drive shaft cannot be removed by hand. b. Using a screwdriver, remove the snap ring from the inboard joint shaft

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REMOVAL 1. Remove the wheel and tire. 2. Drain the gear oil or transaxle fluid. 3. Remove the cotter pin and driveshañ nut from the front hub 4. Remove the 2 bolts and disconnect the ball joint from the knuckle. 5. Using a plastic hammer, separate the driveshaft from the axle hub. 6. Push the axle hub toward the outside of the vehicle, and separate the driveshaft from the axle hub. Center bearing bracket 7. Insert a pry bar between the center bearing bracket and the driveshaft, and then pry the driveshaft from the transaxle. (2.7L ENG.) NOTE: Do not pull on the driveshaft, doing so will damage the D.O.J, or T.J. be sure to use the pry bar.Insert a pry bar between the transaxle case and the driveshaft, and pry the driveshaft from the transaxle (Except 2.7L ENG.) NOTE: Do not pull on the driveshaft, doing so will damage the D.O.J.; be sure to use the pry bar. Do not insert the pry bar deeply enough to damage the oil seal CAUTION: Do not apply the vehicle weight to the wheel bearingwhile the driveshaft is disconnected If the vehicle’s weight must be applied (because of vehicle movement or some other reason), use the special toot to hold the wheel bearing, as shown in the figure. 9. After releasing the auto tensioner, remove the drive belt. (2.7L ENG.) 10. Remove the alternator assembly (2.7L ENG.) 11. Remove the center bearing bracket mounting bolts. Insert the pry bar between the center bearing bracket and the cylinder block to disconnect the bracket from the cylinder block

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Knock-in radial sealing ring with 65 mm OD by means of installer, until installer is flush with bearing cap. Note: Coat radial sealing ring together with rubber-coated sheet-metal jacket on OD with rubber sliding compound “napthalene H or hypoid gear oil”. Attention! On vehicles with large rear axle center piece there are 2 versions of bearing caps for radial sealing rings with 65 mm dia . On 1st version, push radial sealing ring inwards until punch rests against lug for dirt labyrinth of bearing cap. On 2nd version, push radial sealing ring inward until punch is flush with lower edge of chamfer (lug for dirt labyrinth is made shorter) of bearing cap. To avoid excessive pressure, use spacing ring made according to drawing. Radial Sealing Ring Correctly Inserted

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REMOVAL 1. Drain the clutch fluid and transaxle gear oil. 2. Remove the transaxle assembly. 3. Insert the special tool (09411-25000) in the clutch disc to prevent the disc from falling. 4. Loosen the bolts that attach the clutch cover to the flywheel in a star pattern.
5. Loosen the bolts in succession, one or two turns at a time, to avoid bending the cover flange. CAUTION: DO NOT clean the clutch disc or release bearing with cleaning solvent.
INSPECTION CLUTCH COVER ASSEMBLY 1. Check the diaphragm spring end for wear and uneven height. Replace if wear is evident or height difference exceeds the limit. Limit: 0.3 mm (0.012 in.) 2. Check the pressure plate surface for wear, cracks and color change.