Overhaul (Disassembly and Assembly)
Disassembly and Assembly
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DISASSEMBLY
Front Case and Rear Case
1. Remove drain plug and filler plug.
2. Remove mainshaft oil seal from front case, using a flat-bladed screwdriver.
CAUTION: Be careful not to damage the front case and mainshaft.
3. Remove front oil seal from front case, using a flat-bladed screwdriver.
CAUTION: Be careful not to damage the front case and front drive shaft.
4. Remove self-lock nut.
5. Put a matching mark on the end of mainshaft. The mark should be in line with the mark on the companion flange.
CAUTION: For matching mark, use paint. Do not damage mainshaft.
6. Remove companion flange, using a puller.
CAUTION: Be careful not to damage the companion flange.
7. Remove rear oil seal from rear case, using a puller.
Tool number: KV381054S0 (J-34286)
CAUTION: Be careful not to damage the rear case.
8. Remove spacer from mainshaft.
9. Remove front case and rear case fixing bolts, then remove harness bracket.
10. Separate front case and rear case. Then, remove front case by levering it up with a tire lever or the like.
CAUTION: Be careful not to damage the mating surface.
11. Remove snap ring from front case.
12. Remove mainshaft bearing from front case, using a drift.
Tool number: KV38100300 (J-25523)
13. Remove drive chain and front drive shaft while tapping front drive shaft with plastic hammer.
CAUTION: Be careful not to tap drive chain.
14. Remove oil gutter from rear case.
15. Remove oil cover bolt and sensor fixing bolt from rear case. And then, remove oil cover.
16. Remove retainer from transfer assembly harness connector.
17. Remove transfer assembly harness connector from rear case.
18. Remove O-ring from transfer assembly harness connector.
19. Remove mainshaft assembly from rear case, using a drift.
Tool number: ST33052000 ( - )
20. Remove snap ring from rear case.
21. Remove rear bearing from rear case, using a drift.
Tool number
A: ST30611000 (J-25742-1)
B: ST35321000 ( - )
22. Remove baffle plate from rear case.
23. Remove breather tube from rear case.
Mainshaft Assembly
1. Separate front case and rear case, then remove mainshaft assembly.
2. Remove snap ring from mainshaft.
3. Remove spacer from mainshaft.
4. Remove electric controlled coupling and sprocket from mainshaft.
5. Remove needle bearing from mainshaft.
Front Drive Shaft and Drive Chain
1. Separate front case and rear case.
2. Remove drive chain and front drive shaft while tapping front drive shaft with plastic hammer.
CAUTION: Be careful not to tap drive chain.
3. Remove front drive shaft front bearing, using drift and puller.
Tool number: ST31214000 (J-25269-B)
4. Remove front drive shaft rear bearing, using drift and puller.
Tool number: ST31214000 (J-25269-B)
INSPECTION
Cases
Check items below. If necessary, replace them with new ones.
^ Contact surfaces of bearing for wear, damage, etc.
^ Damage and cracks of case.
Bearing
Check items below. If necessary, replace them with new ones.
^ Damage and rough rotation of bearing.
Shaft
Check items below. If necessary, replace them with new one.
^ Damage, peeling, dent, uneven wear, bending, etc. of shaft.
Gears and Chain
Check items below. If necessary, replace them with new ones.
^ Excessive wear, damage, peeling, etc. of gear and chain.
ASSEMBLY
Front Drive Shaft and Drive Chain
1. Install front drive shaft front bearing, using drifts.
Tool number: ST33200000 (J-26082)
2. Install front drive shaft rear bearing, using a drift.
Tool number: KV38104010 ( - )
3. Install drive chain to front drive shaft.
CAUTION: Identification mark of drive chain should be in the side of front bearing of front drive shaft.
4. Install drive chain to mainshaft, and then install tap front drive shaft with plastic hammer. Press-fit rear bearing of front drive shaft to rear case.
CAUTION: Be careful not to tap drive chain.
5. Install front case to rear case.
Mainshaft Assembly
1. Install needle bearing to mainshaft.
CAUTION: Apply [1][2]ATF to periphery of needle bearing.
2. Install sprocket and electric controlled coupling to mainshaft.
3. Install spacer to main shaft.
4. Install snap ring to mainshaft.
CAUTION: Do not reuse snap ring.
5. Install mainshaft assembly to rear case, then install front case and rear case.
Front Case and Rear Case
1. Install breather tube, with plastic hammer.
CAUTION: Pay attention to the direction of breather tube.
2. Install baffle plate to rear case, and tighten bolt to the specified torque. Refer to TF-45, "COMPONENTS".
3. Install rear bearing to rear case, using a drift.
Tool number: KV38104010 ( - )
CAUTION: Apply [1][2]ATF to inside of rear bearing.
4. Install snap ring to rear case.
CAUTION: Do not reuse snap ring.
5. Install mainshaft assembly to rear case, using a drift.
Tool number: ST35321000 ( - )
CAUTION: [1][2]ATF should be applied to contact surface of mainshaft and rear bearing.
6. Install O-ring to transfer assembly harness connector.
CAUTION:
^ Do not reuse O-ring.
^ Apply [1][2]ATF to O-ring.
7. Install transfer assembly harness connector into rear case.
8. Install retainer to transfer assembly harness connector.
9. Set temperature sensor and tighten bolt to the specified torque. Refer to TF-45, "COMPONENTS".
10. Hold electric controlled coupling harness with oil cover hold plate, install oil cover to rear case, and tighten bolt to the specified torque. Refer to TF-45, "COMPONENTS".
CAUTION: The harness should be guided by a cut portion.
11. Install oil gutter to rear case.
CAUTION: The tip of oil gutter should be put into rear case groove.
12. Install drive chain to front drive shaft.
CAUTION: Identification mark of drive chain should be in the side of front bearing of front drive shaft.
13. Install drive chain to mainshaft, and then install tap front drive shaft with plastic hammer. Press-fit rear bearing of front drive shaft to rear case.
CAUTION: Be careful not to tap drive chain.
14. Install mainshaft bearing to front case, using a drift.
Tool number: ST30621000 (J-25742-5)
15. Install snap ring to front case.
CAUTION: Do not reuse snap ring.
16. Apply liquid gasket to mating surface of rear case.
^ Use Genuine Anaerobic Liquid Gasket or equivalent.
CAUTION: Remove old sealant adhering to mounting surfaces. Also remove any moisture, oil, or foreign material adhering to application and mounting surfaces.
17. Set front case to rear case.
CAUTION: Be careful not to damage the mating surface transmission side.
18. Tighten front case and rear case fixing bolts to the specified torque. Refer to TF-45, "COMPONENTS".
19. Install spacer to mainshaft.
CAUTION: Apply [1][2]ATF to spacer.
20. Install rear oil seal to rear case, using a drift.
Dimension A: 6.7 - 7.3 mm (0.264 - 0.287 inch)
Tool number
A: ST30720000 (J-25405)
B: KV40104830 ( - )
CAUTION:
^ Do not reuse rear oil seal.
^ Apply [1][2]ATF to rear oil seal.
^ When installing, do not incline rear oil seal.
21. Install companion flange while align the matching mark of mainshaft with the mark of companion flange.
22. Tighten self-lock nut to the specified torque, with flange wrench. Refer to TF-45, "COMPONENTS".
CAUTION: Do not reuse self-lock nut.
23. Install mainshaft oil seal until it is flush with end face of front case, using drift.
Tool number: ST30720000 (J-25405)
CAUTION:
^ Do not reuse mainshaft oil seal.
^ Apply [1][2]ATF to mainshaft oil seal.
^ When installing, do not incline mainshaft oil seal.
24. Install front oil seal until it is flush with end face of front case, using drift.
Tool number: ST27862000 ( - )
CAUTION:
^ Do not reuse front oil seal.
^ Apply [1][2]ATF to front oil seal.
^ When installing, do not incline front oil seal.
25. Apply sealant to threads of drain plug. Then install it to rear case and tighten to the specified torque. Refer to TF-45, "COMPONENTS".
^ Use Genuine Silicone RTV or equivalent.
CAUTION: Remove old sealant and oil adhering to threads.
26. Set gasket to filler plug. Install it to rear case and tighten to the specified torque. Refer to TF-45, COMPONENTS.
CAUTION: Do not reuse gasket.