Part 2
DISASSEMBLY(continued)Center Case
1. Remove the rear case assembly.
2. Remove the front case assembly.
3. Hold the front drive shaft with one hand and tap to remove the front drive shaft with the drive chain.
CAUTION: Do not tap drive chain.
4. Remove the front drive shaft front bearing using Tools.
Tool number
A: ST33052000 ( - )
B: ST30031000 ( - )
5. Remove the front drive shaft rear bearing using Tools.
Tool number
A: ST33052000 ( - )
B: ST30031000 ( - )
6. Remove the NEUTRAL-4LO and ATP switches.
7. Remove the bolts and main oil pump cover.
8. Remove the outer gear, inner gear and main oil pump housing from the center case.
9. Remove the seal ring from the main oil pump cover.
10. Remove the stem bleeder from the bleed hole.
11. Remove the snap ring and washer holder from the mainshaft.
12. Remove the C-rings from the mainshaft using suitable tool.
13. Set the center case on the press stand. Remove the mainshaft from the center case.
14. Remove the snap ring from the mainshaft using suitable tool.
15. Remove the thrust needle bearing from the press flange.
16. Press the press flange until the snap ring is out of place using Tools.
Tool number
A: ST22452000 (J-34335)
B: ST30911000 ( - )
C: KV31103300 ( - )
17. Remove the snap ring from the mainshaft using suitable tool.
18. Remove the press flange from the mainshaft.
19. Remove the return spring assembly from the clutch hub.
20. Remove each plate from the clutch drum.
21. Remove the snap ring from the mainshaft.
22. Remove the mainshaft from the clutch drum and clutch hub using suitable tool.
23. Remove the needle bearing and spacer from the mainshaft.
24. Remove the snap ring from the clutch hub using suitable tool.
25. Remove the oil pressure check plug from the oil pressure check port.
26. Apply air gradually from the oil pressure check port, and remove the clutch piston assembly from the center case.
27. Remove the thrust needle bearing race from the clutch piston by hooking a edge into 3 notches of the thrust needle bearing race using suitable tool.
CAUTION: Do not damage clutch piston or thrust needle bearing race.
28. Remove the two D-rings from the clutch piston.
29. Remove the mainshaft rear bearing from the center case using Tool.
Tool number: KV38100300 (J-25523)
30. Remove the two bolts and oil strainer.
31. Remove the two O-rings from the oil strainer.
32. Remove the snap ring. Then push the connector assembly into the center case to remove the control valve assembly.
33. Remove the control valve assembly bolts.
34. Remove the control valve assembly.
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.
35. Remove the lip seals from the center case.
CAUTION: 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.
36. Disassemble the control valve assembly with the following procedure.
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.
a. Remove all the bolts except for the two shown.
b. Remove the following from the control valve assembly:
^ Clutch pressure solenoid valve
^ Clutch pressure switch
^ 2-4WD shift solenoid valve
^ Line pressure switch
^ Transfer fluid temperature sensor
c. Remove the O-rings from each solenoid valve, switch and terminal body.
d. Place the control valve with the lower body facing up. Remove the two bolts, and then remove the lower body and separator plate from the upper body.
CAUTION: Do not drop relief balls. Detach lower body carefully.
e. Make sure the reverse balls, relief balls, relief springs, accumulator pistons and valve springs are securely installed as shown, and remove them.
f. Remove the retainer plates.
g. Remove each retainer plate (1), plug (2), control valve (3) and spring (4) from the upper body (5).
37. Remove the transfer motor bolts and motor from the center case. Then remove the O-ring from the transfer motor.
38. Remove the sub oil pump cover bolts.
39. Thread two bolts (M4 x 0.8) into the holes of sub oil pump cover as shown, and pull out to remove the sub oil pump assembly.
40. Remove the outer gear and inner gear from the sub oil pump housing.
41. Remove the oil filter bolts and oil filter.
CAUTION:
^ Do not damage center case and oil filter.
^ Loosen bolts and detach oil filter evenly.
42. Remove the O-rings (1) from the oil filter (2).
43. Remove the oil filter stud from the oil filter.
44. Remove the O-ring from the oil filter stud.