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Новосибирский государственный технический университет
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[НЕСОРТИРОВАННОЕ]
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4WD_JM.doc
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6 . Wiring diagram (for cbs)

PIN DESCRIPTION

* CBS: Conventional Brake System (without ABS)

7. 4Wd coupling assembly

7.1 Specal tools

TOOLS

(PART NUMBER & NAME)

ILLUSTRATION

USE

09432-33200

Bearing removing plate

Removal of 4WD coupling flange oil seal

09478-26000

Flange oil seal installer

Installation of 4WD coupling flange oil seal

09478-26100

Back plate remover

Removal of 4WD coupling back plate

7.2 Torque

ITEMS

Nm

kgcm

lbft

Coupling flange lock nut

214-218

2140-2180

158-161

EMC (Electric Magnetic Clutch) mounting nuts (3EA)

8-11

80-110

6-8

Rear propellar shaft to 4WD coupling mounting bolts (3EA)

100-120

1000-1200

74-88

4WD coupling to rear differential carrier bolts

60-65

600-650

44-48

7.3 Removal and installation

Connecting bolts (3EA)

1. Remove the 4WD coupling bolts (3EA) mounted to the rear propellar shaft.

Coupling assembly

Flat tool

2. Using a flat tool, separate the propellar shaft from 4WD coupling.

Coupling assembly

Rear propellar shaft

Socket

Coupling assembly

Rear differential carrier

3. Remove the rear axle (Differential carrier) bolts mounted to the 4WD coupling.

Magnetic clutch connector

4. Remove the electric magnetic clutch connector.

Flat tool

Rear differential carrier

5. Using a flat tool, separate the 4WD coupling assembly from the rear differential carrier.

Coupling assembly

6. Remove the 4WD coupling assembly.

7. Installation is the reverse of the removal.

7.4 Disassembly

Nut

Flange

1. Remove the coupling flange mounting nut.

Spacer

2 . Remove the flange spacer.

3

Oil seal

. Remove the coupling flange oil seal.

3-way puller

Flange

 4. Using a general tool, 3-way puller, remove the flange assembly.

Suitable tool

09432-33200

Oil seal

Press

5. Remove the flange oil seal using special tool (09432-33200).

Coupling case

6

Clutch housing

. Remove the coupling case assembly.

Oil seal

1) Remove the coupling case oil seal.

NOTE

Insert the (-) driver between the oil seal and the clutch housing, then remove the oil seal.

Snap ring

2) Remove the snap ring.

3) Remove the Electric Magnetic clutch mounting nuts (3EA).

Magnetic clutch

Wave spring

Back plate

 7. Remove the wave spring for fixing the back plate and the secondary clutch assembly.

Snap ring

8. Remove the snap ring.

9. After removing the oil seal, remove the snap ring.

09478-26100

Back plate & secondary clutch assembly

 10. Remove the back plate and the secondary clutch assembly simultaneously using special tool (09478-26100).

Back plate

1) Separate the back plate from the input shaft.

Plate

Disc

 2) Remove the plates (10EA) and the discs (10EA).

Armature

3) Remove the armature.

Input shaft

4) Remove the input shaft.

Steel ball

11. Remove the steel balls (6EA) on the base cam.

Base cam

12. Remove the base cam.

Thrust washer

13. Remove the thrust washer.

Thrust race

14. Remove the thrust race.

Snap ring

15. Remove the clutch of the primary clutch.

Plate

16. Remove the plate of the primary clutch.

NOTE

Additionally remove each 2EA discs and plates alternately.

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