Disassembly and Assembly

Disassembly and Assembly

DISASSEMBLY
Removal front case








1. Remove front case fixing bolts.





2. Insert tire lever as shown in the figure, separate front case and front case. Then, remove rear case by levering it up with a tire lever or the like.

CAUTION: Be careful not to damage the mating surface.





3. Remove the front oil seal and main shaft oil seal, from front case.





4. Remove snap ring from front case.





5. Remove input bearing from front case.

Rear case





1. Remove the drive chain and front drive shaft from rear case.





2. Remove lock nut from main shaft using the drive pinion flange wrench.
Tool number: KV38108300 (J44195)





3. Put matching mark on the end of the main shaft corresponding to the B position matching mark on the companion flange.





4. Remove the companion flange from main shaft using a suitable puller.
5. Remove spacer at the end of companion flange.

CAUTION: Be careful not to damage oil seal.





6. Remove the oil gutter from rear case.





7. Remove the oil cover bolt from rear case.





8. Remove the retainer into connector.
9. Remove the coupling connector into rear case.





10. Remove the main shaft and electric controlled coupling from rear case using a press.





11. Using a puller, remove the rear oil seal from rear case.
Tool number: KV381054S0 (J34286)





12. Remove snap ring from rear case.

CAUTION: Do not reuse snap ring.

13. Remove the main shaft rear bearing from rear case.





14. Remove the baffle plate from rear case.

Front drive shaft





1. Remove the front drive shaft front bearing from front drive shaft.
Tool number: ST33061000 (J8107-2)





2. Remove the front drive shaft rear bearing from front drive shaft using a.
Tool number: ST35322000 (-)

Main shaft and electric controlled coupling





1. Remove the snap ring from main shaft.
2. Remove the spacer, electric controlled coupling, sprocket and needle bearing from main shaft.

INSPECTION
Gears
^ Check the gear faces and shaft for wear, cracks, damage, and seizure.

Bearings
^ Check for seizure, peeling, wear, corrosion, sticking/abnormal noise/roughness in hand turning, and other damage.

CAUTION:
^ When replacing the bearing, always replace the inner race and outer race as a pair.

Front case and rear case
^ Replace with a new one if found any wear or cracks on the contact sides of the case.

Washers
^ Check for seizure, damage, and unusual wear.

Oil seals
^ Discard old oil seals, replace with new ones.
^ If wear, deterioration of adherence (sealing force of lips), or damage is detected on the lips, replace them.

Snap ring
^ Discard old snap rings, replace with new ones.

Lock nut
^ Discard old lock nut, replace with new ones.

ASSEMBLY
Rear case





1. Install the baffle plate into rear case.
2. Install the main shaft rear bearing into rear case.





3. Install the snap ring into rear case.

CAUTION: Do not reuse snap ring.





4. Apply multi-purpose grease to oil seal lips. Install the oil seal with a drift to fit the position as shown in the figure.
Tool number: KV40104830 (-)

CAUTION:
^ Discard old oil seals; replace with new ones.
^ Apply multi-purpose grease onto oil seal lips, and gear oil onto the circumference of the oil seal.

Main shaft and electric controlled coupling





1. Fixing needle bearing to main shaft with grease.
2. Install the sprocket, electric controlled coupling and spacer into main shaft.





3. Install the snap ring into main shaft.

CAUTION: Do not reuse snap ring.

Front drive shaft





1. Using a press and drift, install the front drive shaft front bearing into front drive shaft.
Tool number: ST30022000(-)





2. Using a press and drift, install the front drive shaft rear bearing into front drive shaft.
Tool number: ST30914000(-)

Front case
1. Install the main shaft bearing into front case.





2. Install the snap ring into front case.

CAUTION: Do not reuse snap ring.





3. Using a drift, install the oil seal into front case.
Tool number: ST27862000 (-)

CAUTION: Install oil seal after applying grease in the case hole.





4. Using a drift, install the main shaft oil seal into front case.
Tool number: ST30613000 (-)

CAUTION: Install oil seal after applying grease in the case hole.

Install rear case





1. Using a press and drift, install the main shaft into rear case. When installing, make sure to fit electric controlled coupling detent to rear case ditch.
Tool number: ST30022000 (-)





2. Install the coupling connector into rear case.
3. Install coupling connector to the ring after applying grease to the ring.
4. Install the retainer into connector.





5. Install the oil cover and temperature sensor bolt into rear case. Using harness dolly of oil cover, install electric controlled coupling harness between dolly and case.
6. Apply grease to both side of spacer. Insert the spacer from the back end of main shaft.





7. Install the oil gutter into rear case.





8. Install the companion flange into main shaft.
9. Install companion flange lock nut into companion flange.

CAUTION: Discard old lock nut, replace with new ones.





10. Install the drive chain and front drive shaft into rear case.





11. Apply Genuine Liquid Gasket or equivalent to the entire front case mounting surface of rear case as shown in the figure.

CAUTION: Be careful not to damage the mating surface.





12. Install front case into rear case.

CAUTION: Be careful not to damage the mating surface transmission side.








13. Tighten bolts to specified torque.