Final Assembly

Final Assembly





1. Install C-rings to mainshaft rear bearing.





2. Check speedometer drive gear teeth for abnormal wear. Set speedometer drive gear properly on mainshaft, and secure it with snap ring.
- Do not reuse snap ring.





3. Apply Genuine Anaerobic Liquid Gasket or equivalent to the entire center case mounting surface of front case as shown in the figure.

CAUTION: Remove all foreign materials such as water, oil and grease from center case and front case mating surfaces.





4. Make sure the two claws of oil gutter are securely attached to slots in center case.





5. With the claws of oil gutter held by a finger, install center case assembly to front case assembly.

CAUTION: Pay careful attention so that mainshaft end does not damage radial needle bearing in sun gear assembly.

6. Tap center case lightly with a rubber hammer or the like and press-fit front drive shaft bearing into front case.





7. Make sure oil gutter rear end protrudes from point "A" in the figure.
8. Tighten bolts to specified torque.
41 - 48 Nm (4.2 - 4.9 kg-m, 30 - 35 ft. lbs.)
- Be sure to install air breather hose clamp, connector bracket and harness clip.





9. Fit double-flat end of oil pump shaft into slot of main oil pump and install it.

NOTE: When oil pump shaft is rotated slightly, it drops into position where both parts fit.





10. Install stem bleeder to center case.





11. Remove rear oil seal.
- Do not reuse oil seal.





12. Apply ATF to the circumference of new rear oil seal, and tap it using a drift as shown in the figure so that it is aligned with case tip face.
- Apply multipurpose grease to oil seal lip.





13. Apply Genuine Anaerobic Liquid Gasket or equivalent to entire rear case mounting surface of center case as shown in the figure.

CAUTION:
- Remove all foreign materials such as water, oil, and grease from center case and rear case mating surfaces.
- Be careful not to allow sealing fluid to clog bleeder hole.

14. Install rear case to center case, and tighten bolts to specified torque.
41 - 48 Nm (4.2 - 4.9 kg-m, 30 - 35 ft. lbs.)
- Be sure to attach harness clips.





15. Remove all the gasket fluid from switch mounting area and inside rear case, with ATP switch and neutral-4LO switch threaded in 1 to 2 pitches, apply Genuine Thread Sealant or equivalent to the thread of the switches and tighten it to specified torque.
15 - 20 Nm (1.5 - 2.0 kg-m, 11 - 14 ft. lbs.)
16. Install rear case assembly to center case assembly.





17. Install companion flange to front drive shaft, and tighten mounting nut.
226 - 324 Nm (23.0 - 33.0 kg-m, 166 - 239 ft. lbs.)