Center Case

Center Case
DISASSEMBLY

1. Remove oil pump shaft from main oil pump.

2. Remove stem bleeder from bleeder hole.

3. Remove lock nut from companion flange.
- Do not reuse lock nut.

4. Remove companion flange.

5. Remove bolts.

6. Insert screwdrivers as shown in the figure, and separate counter case from front case. Then, remove center case by levering it up with a tire lever or the like.

7. Remove snap ring from mainshaft.
- Do not reuse snap ring.

8. Remove C-rings from mainshaft bearing.

Front Drive Shaft and Drive Chain

1. Remove oil gutter from center case.
2. With front drive shaft held by one hand as shown in the figure, tap center case with a plastic hammer to remove it with drive chain.
- Do not tap drive chain with a plastic hammer.

3. Set a puller (ST30021000) and an adapter (ST33052000). Remove front drive shaft front bearing.

4. Set the puller (ST30021000) and the adapter (ST33052000). Remove front drive shaft rear bearing.

Mainshaft and Clutch Drum

1. Remove mounting bolts to detach baffle plate.

2. Set center case to press stand. Remove mainshaft from center case.

3. Remove thrust needle bearing from press flange.

4. Remove seal ring from mainshaft.
- Do not reuse seal ring.

5. Set a drift (KV31103300), a support ring (KV40104710), a support ring (ST27863000) and a drift (ST35271000) to press flange as shown in the figure. Press drift until snap ring is out of place.

6. Remove snap ring from mainshaft.
- Do not reuse snap ring.

7. Remove washer.

8. Remove press flange from mainshaft.

9. Remove return spring assembly from clutch hub.

10. Remove each plate from clutch drum.

11. Remove snap ring from mainshaft.
- Do not reuse snap ring.

12. Tap mainshaft with a plastic hammer to remove it from clutch drum and clutch hub.
13. Remove needle bearing from mainshaft.

Clutch Piston

1. Remove oil pressure check plug from oil pressure check port.

2. Apply air gradually from oil pressure check port, and remove clutch piston from center case.

3. Remove lip seal and D-ring from clutch piston.
- Do not reuse lip seal and D-ring.
4. Remove thrust needle bearing race from clutch piston by hooking a screwdriver edge into 4 notches of thrust needle bearing race.

Control Valve

CAUTION:
- Do not reuse any part that has been dropped or damaged.
- Make sure valve is assembled in the proper direction.
- Do not use a magnet because residual magnetism stays during disassembly.

1. Remove bolts, and detach oil strainer.

2. Remove O-rings from oil strainer.
- Do not reuse O-rings.

3. Remove bolts for control valve.

4. Remove snap ring. Then push terminal assembly into center case to remove control valve assembly.

5. Remove lip seals from center case.
- Do not reuse lip seals.
- There are two kinds of lip seals (lip seal of large inner diameter: 5 pieces, lip seal of small inner diameter: 2 pieces). Confirm the position before disassembly.

6. Remove all bolts except for two.

7. Remove 4WD solenoid valve, clutch pressure switch, 2-4WD shift solenoid valve, line pressure switch, and transfer fluid temperature sensor from control valve assembly.
8. Remove O-rings from each solenoid valve, switch and terminal body.
- Do not reuse O-rings.

9. Place control valve with lower body facing up, remove two mounting bolts, and then remove lower body and separator plate from upper body.

CAUTION:
- Be careful not to drop relief balls. Detach lower body carefully.
- Do not reuse separator plate.

10. Make sure reverse balls, relief balls and relief springs, accumulator pistons, valve springs, and filters are securely installed as shown in the figure, and remove them.