Front Case

Front Case
DISASSEMBLY





1. Remove rear case from center case.
2. Remove front case from center case.

Shift Rod Components





1. Remove check plug, then check spring and check ball.
2. Remove wait detection switch.





3. Remove shift rod components together with 2-4 sleeve and L-H sleeve.





4. Remove 2-4 sleeve and L-H sleeve from 2-4 fork and L-H fork respectively.





5. Drive out roll pin from shift rod.
- Do not reuse roll pin.





6. Remove L-H fork, 2-4 fork, shift fork spring and fork guide from shift rod.

Planetary Carrier, Sun Gear and Internal Gear





1. Remove radial needle bearing from sun gear.





2. Remove bolts to detach transfer cover.
- Do not reuse bolts.





3. Remove oil seal from transfer cover.
- Do not reuse oil seal.





4. Remove snap ring from main gear bearing.
- Do not reuse snap ring.





5. Remove sun gear by tapping it lightly.





6. Remove snap ring from sun gear.
- Do not reuse snap ring as it is a selective part.
7. Remove washer from sun gear.








8. Set an adapter to sun gear as shown in the figure. Remove sun gear from planetary carrier. Remove main gear bearing, bearing race and thrust needle bearing (front and rear of planetary carrier) from sun gear.





9. Remove plug bolt, then remove resist spring and pin.





10. Remove snap ring, and remove internal gear.
- Do not reuse snap ring.





11. Remove front oil seal.
- Do not reuse oil seal.
12. Loosen nut of outer lever assembly to pull out cotter pin, and remove outer lever.
13. Remove inner lever assembly.