Steps 31-61

31. Install the mode fork and the shift rail assembly in the front case.
- The shift rail must bottom in the case.





32. CAUTION: Install the mainshaft assembly so that the synchronizer strut bears against one of the synchronizer or mode sleeve teeth.

Install the mainshaft.





33. Install the clutch gear.





34. Install the drive sprocket, the driven sprocket, and the drive chain as an assembly.





35. Install the mode spring.





36. Install a new drive sprocket retaining ring.





37. Install a new driven sprocket retaining ring.





38. Using the special tools and a suitable press, install a new ball bearing.





39. Install a new ball bearing retaining ring.





40. NOTE: The identification numbers on the bearing must face the special tool.

Using the special tools and a suitable press, install a new needle bearing.





41. Install the chip collector magnet.





42. Install the oil tube.





43. Clean both case mating surfaces with metal surface cleaner.





44. NOTE: The silicone bead must be no larger than 2 mm (0.08 inch) in diameter.

Apply a bead of silicone gasket and sealant to the joint face of the case.
- The bead must be on the inside of the bolt holes, toward the inside of the case.





45. Position the rear case half onto the front case half.





46. NOTE: Use a crisscross pattern when tightening the bolts.

Install the 25 new bolts retaining the rear case to the front case.
47. Install the new retaining ring.
1 Install the special tool.
2 Install the new retaining ring.
- Remove the special tool.

48. NOTE: Prior to assembly, verify that the O-ring is in the oil pump pickup inlet.

Slide the oil pump assembly onto the mainshaft and connect the oil tube.





49. NOTE: The identification numbers on the needle bearing must face the special tool.

Using the special tools and a suitable press, install a new needle bearing.
50. Clean the rear case and rear retainer mating surfaces with metal surface cleaner.





51. Apply a bead of silicone gasket and sealant to the rear retainer joint face.





52. Position the rear retainer on the rear case.





53. Install the eight new bolts retaining the rear retainer to the case.





54. Using the special tools, install a new rear output seal.





55. Using the special tools, install a new slinger on the rear flange, if removed.





56. Install the rear flange.
- Use the special tool to prevent the flange from turning while installing a new nut.





57. CAUTION: Do not use air tools. Install the drain and fill plugs.





Electric shift transfer case

58. NOTE: Apply a coat of multi-purpose grease to the motor adapter.

Install the gear motor encoder assembly.





Manual shift transfer case
59. Install the 3 position switch.





60. Tighten the nut.





All transfer cases
61. Remove the transfer case from the special tool.