Assembly

Disassembly and Assembly

Components:

ASSEMBLY

1. Install breather tube.

CAUTION: Install breather tube in the direction shown.

2. Install baffle plate to front case, and tighten bolt to the specified torque. Refer to "COMPONENTS".

CAUTION: Install baffle plate by pushing it in the direction shown while tightening the bolt.

3. Install the input bearing to front case, using Tool.
Tool number: ST30720000 (J-25405)

4. Install new snap ring to front case.

CAUTION: Do not reuse snap ring.

5. Install internal gear with groove facing up into front case.

6. Install new snap ring to front case.

CAUTION: Do not reuse snap ring.

7. Install the planetary carrier assembly and sun gear assembly to front case, using Tool.
Tool number: KV38100200

8. Install new snap ring to sun gear.

CAUTION:
^ Do not reuse snap ring.
^ Do not damage the sun gear.

9. Set L-H sleeve together with L-H shift fork assembly onto planetary carrier assembly.

10. Install control shift rod assembly to front case.

CAUTION: Set pin of L-H shift fork assembly into the groove of drum cam.

11. Turn control shift rod assembly fully counterclockwise.

12. Install L-H shift rod assembly through L-H shift fork assembly opening to front case.

CAUTION: Set pin of L-H shift rod assembly into the groove of drum cam.

13. Install mainshaft to sun gear assembly
14. Apply ATF to spacer and periphery of needle bearing, install to mainshaft.

15. Set front drive shaft and sprocket to drive chain.

CAUTION: Identification mark of drive chain should be on the side of rear bearing of front drive shaft.

16. Install drive chain together with front drive shaft and sprocket to front case.

17. Install 2-4 sleeve and 2-4 shift fork assembly to mainshaft.

CAUTION:
^ Install with proper orientation of 2-4 sleeve.
^ Install 2-4 shift fork with engaging the grooves of 2-4 shift fork in the retaining pin of 2-4 shift bracket.

18. Install new snap ring to L-H shift rod assembly, using suitable tool.

CAUTION: Do not reuse snap ring.

19. Install clutch gear to mainshaft.

20. Install new snap ring to mainshaft, using suitable tool.

CAUTION: Do not reuse snap ring.

21. Install oil pump assembly to mainshaft.

22. Install new snap ring to mainshaft, using suitable tool.

CAUTION: Do not reuse snap ring.

23. Install retainer to mainshaft.

CAUTION: Set the projection of oil pump assembly to identification hole, and then align locating hole of retainer to L-H shift rod assembly.

24. Install the mainshaft rear bearing to mainshaft, using Tool.
Tool number: KV32102700

CAUTION: Do not push too hard in order to avoid snap rings becoming dislodged from mainshaft.

25. Install new snap ring to mainshaft, using suitable tool.

CAUTION: Do not reuse snap ring.

26. Install spacer to control shift rod.

27. Apply liquid gasket to mating surface of front case.
^ Use Genuine Anaerobic Liquid Gasket or equivalent. Refer to GI-45, "Recommended Chemical Products and Sealants". Tools and Equipment

CAUTION: Remove old sealant adhering to mating surfaces. Also remove any moisture, oil, or foreign material adhering to application and mating surfaces.

28. Install rear case to front case.

29. Tighten bolts to specified torque. Refer to "COMPONENTS".

CAUTION: Be sure to install the harness brackets and air breather hose clamp.

30. Install the retainer bolts with new gaskets. Tighten the bolts to the specified torque. Refer to "COMPONENTS".

CAUTION:
^ Do not reuse gasket.
^ Tighten them to the specified torque again.

31. Install new input oil seal to front case, using Tools.
Dimension A: 4.0 - 4.6 mm (0.157 - 0.181 inch)
Tool number:
A: ST30720000 (J-25405)
B: KV40104830

CAUTION:
^ Do not reuse oil seal.
^ Apply petroleum jelly to oil seal.

32. Install new rear oil seal until it is flush with end face of rear case, using Tool.
Tool number: KV38100500

CAUTION:
^ Do not reuse oil seal.
^ Apply petroleum jelly to oil seal.

33. Apply petroleum jelly to the circumference of the new dust cover. Position the new dust cover using the identification mark as shown.

CAUTION:
^ Do not reuse dust cover.
^ Position the identification mark at the position shown.

34. Install new dust cover to the rear case, using Tool.
Tool number: KV401 05310

CAUTION:
^ Do not reuse dust cover.
^ Apply petroleum jelly to dust cover.

35. Apply sealant to threads of wait detection switch (gray). Then install it to rear case and tighten to the specified torque. Refer to "COMPONENTS".
^ Use Genuine Silicone RTV or equivalent.

CAUTION: Remove old sealant and oil adhering to threads.

36. Apply sealant to threads of 4LO switch (gray with green paint) and ATP switch (black). Then install them to front case and tighten to the specified torque. Refer to "COMPONENTS".
^ Use Genuine Silicone RTV or equivalent.

CAUTION: Remove old sealant and oil adhering to threads.

37. Install new front oil seal until it is flush with end face of front case, using Tool.
Tool number: KV38100500

CAUTION:
^ Do not reuse oil seal.
^ Apply petroleum jelly to oil seal.

38. Align the matching mark on the front drive shaft with the mark on the companion flange, then install the companion flange.

39. Tighten new self-lock nut to the specified torque, using Tool. Refer to "COMPONENTS".
Tool number: KV40104000

CAUTION: Do not reuse self-lock nut.

40. Install new O-ring to transfer control device.

CAUTION:
^ Do not reuse O-ring.
^ Apply petroleum jelly.

41. Install transfer control device to rear case.

a. Turn control shift rod fully counterclockwise using flat-bladed screwdriver, and then put a mark on control shift rod.

b. Align transfer control device shaft cutout with mark on control shift rod, and install.

NOTE: Turn transfer control device when transfer control device connection does not match.

c. Tighten bolts to the specified torque. Refer to "COMPONENTS".
42. Install the drain plug and filler plug with new gaskets to the rear case. Tighten to the specified torque. Refer to "COMPONENTS".

CAUTION: Do not reuse gasket.