Overhaul

Disassembly

1. Disconnecting the connectors, remove the wiring assembly (A).




2. Remove the TCCU and motor assembly (A) by removing bolts (B-3ea).




3. Remove the dynamic damper (A) by removing bolts (B-4ea).




4. Remove the unlock nut (A).




5. Remove the rear flange (A) by using a puller.




6. Remove the transfer cover bolts (A-17ea).




7. Using the special tool (09215-3C000), separate the transfer cover and case in two parts.




8. Remove the transfer cover (A).

CAUTION:
Do not shake the transfer cover not to damage on matching surface of case & cover and inner parts.




9. Remove the return spring (A).




10. Remove the shift shaft and cam.
11. Remove the clutch housing (A).




12. Remove the lockup clutch (A) with the lockup fork (B).




13. Remove the fork rail (A).




14. Remove the reduction fork (A).




15. Remove the oil pump (B) by removing the magnetic (A).




16. Remove the main shaft (A).




17. Remove the reduction hub (A).




18. Remove the snap ring (A).




19. Remove the front output shaft assembly outward from the case.




20. Remove the snap ring (A) between the carrier (B) and ring gear (C).




21. Remove the ring gear (A).




22. Widen two ends of the snap ring (A) and remove the carrier assembly (B).




23. Pull each wire from the connector housing.




24. Remove the clutch coil nuts (A-3ea).




25. Remove the clutch coil (A).






Reassembly

1. Install the clutch coil (A).




2. Install the clutch coil nuts (A-3ea).




3. Insert each wire to the connector housing.




4. Widen two ends of the snap ring (A) and install the carrier assembly (B).




5. Install the ring gear (A).




6. Install the snap ring (A) between the carrier (B) and ring gear (C).




7. Install the front output shaft assembly outward from the case.




8. Install the snap ring (A).




9. Install the reduction hub (A).




10. Install the main shaft (A).




11. Install the oil filter (B) and the magnetic (A).




12. Install the reduction fork.




13. Install the shift shaft and cam.
14. Install the fork rail (A).




15. Install the lockup clutch (A) with the lockup fork (B).




16. Install the clutch housing (A).




17. Install the return spring (A).




18. Grease the contact surface of the cover and install the transfer cover (A).




19. Install the transfer cover bolts (A-17ea).




20. Install the rear flange (A) by using press.




21. Install the unlock nut (A).




22. Install the dynamic damper (A) by installing bolts (B-4ea).




23. Install the TCCU and motor assembly (A) by installing bolts (B-3ea).




24. Connecting the connectors, install the wiring assembly (A).