Front Case
ASSEMBLYPlanetary Carrier, Sun Gear and Internal Gear
1. Apply ATF to oil seal periphery, and install oil seal so that it is flush with the end face of front case.
- Do not reuse oil seal.
2. Install internal gear with its groove facing snap ring into front case. Then secure it with snap ring.
- Do not reuse snap ring.
3. Remove all the liquid gasket on plug bolt and front case. Apply Genuine Thread Sealant or equivalent to plug bolt, install it to front case and tighten it to specified torque.
- With one crest of plug bolt inserted in the hole, apply Genuine Anaerobic Liquid Gasket or equivalent to the thread.
19 - 25 Nm (1.9 - 2.5 kg-m, 14-18 ft. lbs.)
4. Install snap ring to main gear bearing.
- Do not reuse snap rings.
5. Set main gear bearing to front case, then press it.
6. Install thrust needle bearing to sun gear.
7. Install sun gear to planetary carrier.
8. Set a support (KV40105500) to bushing replacer puller (ST30911000) as shown in the figure, and place planetary carrier on it.
9. Install thrust needle bearing to planetary carrier with its roller facing front case.
10. Measure "C" from the end of sun gear to the roller surface of thrust needle bearing.
11. Measure "D" from the end of sun gear to the main gear bearing contact surface.
12. Calculate end play "E" using "C" and "D" obtained in steps 10 and 11. Select bearing race so that the end play becomes the standard value.
Calculation formula: End play "E" = "C" - "D"
Standard end play: 0.1 - 0.25 mm (0.0039 - 0.0098 inch)
13. Set planetary carrier to press in the status described in step 8. Then install the selected bearing race to planetary carrier.
14. Install front case to planetary carrier. Set a support ring (KV40105310) and an adapter B (KV40105230) to main gear bearing inner race, then press it.
15. Install washer to sun gear assembly, and select proper snap ring so that end play "F" of sun gear is within specifications.
Standard end play "F": 0 - 0.15 mm (0 - 0.0059 inch)
16. Install the selected snap ring.
- Do not reuse snap rings.
17. Apply ATF to the periphery of new transfer cover oil seal, and attach it at 1.5 mm (0.059 inch) from the transfer cover and face.
- Do not reuse oil seal.
18. Apply Genuine Anaerobic Liquid Gasket or to transfer cover mounting surface of front case as shown in the figure.
CAUTION:
- Remove all foreign materials such as water, oil, and grease from mating surfaces of front case and transfer cover.
- Prevent sealing fluid from entering into oil holes of front case.
19. Align oil hole of front case with notch of transfer cover, and tighten bolts.
49 - 58 Nm (5.0 - 5.9 kg-m, 36 - 43 ft. lbs.)
- Do not reuse bolts.
20. Apply petroleum jelly to radial needle bearing, and install it inside sun gear.
21. Install shift rod assembly to front case assembly.
22. Install center case assembly to front case assembly.
23. Install rear case assembly to center case.
Shift Rod Assembly
1. Install fork guide, shift fork spring, 2-4 fork, and L-H fork to shift rod, and secure them with roll pins.
- Do not reuse roll pins.
2. Install 2-4 sleeve and L-H sleeve to each fork.
3. While aligning L-H sleeve with planetary carrier, install shift rod assembly to front case.
4. Remove all the liquid gasket on check plug and front case, and install check ball and check spring to front case. Apply Genuine Thread Sealant or equivalent to check plug, install it to front case, and tighten it to specified torque.
19 - 25 Nm (1.9 - 2.5 kg-m, 14-18 ft. lbs.)
5. Remove all the liquid gasket on the switch fitting and inner side of front case, and with wait detection switch threaded one pitch into the hole, apply Genuine Thread Sealant or equivalent* to the thread, install it, and tighten it to specified torque.
15 - 20 Nm (1.5 - 2.0 kg-m, 11 -14 ft. lbs.)
- Wait detection switch harness connector is black.
6. Install center case assembly to front case assembly.
7. Install rear case assembly to center case.