Disassembly

Disassembly and Assembly

Components:

Components:

DISASSEMBLY
1. Remove drain plug and filler plug.





2. Remove transfer control device from rear case.
3. Remove O-ring form transfer control device.





4. Remove the self-lock nut from the companion flange, using Tool.
Tool number: KV40104000 ( - )





5. Put a matching mark on top of the front drive shaft in line with the mark on the companion flange.

CAUTION: Use paint to make the matching mark on the front drive shaft. Do not damage the front drive shaft.





6. Remove the companion flange, using suitable tool.





7. Remove front oil seal from front case, using Tool.
Tool number: KV381054S0 (J-34286)

CAUTION: Do not damage the front case or front drive shaft.





8. Remove the 4LO switch [gray (with green paint)] and ATP switch (black) from front case.





9. Remove wait detection switch (gray) from rear case.





10. Remove dust cover from rear case, using suitable tool.

CAUTION: Do not damage the rear case.





11. Remove rear oil seal from rear case, using Tool.
Tool number: KV381054S0 (J-34286)

CAUTION: Do not damage the rear case or mainshaft.





12. Remove the input oil seal from front case, using suitable tool.

CAUTION: Do not damage the front case, sun gear or input bearing.





13. Remove the retainer bolts and gaskets.





14. Remove the rear case bolts, harness bracket and air breather hose clamp from the rear case.





15. Separate front case and rear case. Then remove rear case by prying it up, using suitable tool.

CAUTION: Do not damage the mating surface.

16. Remove spacer from the control shift rod.

CAUTION: Do not drop spacer.





17. Remove snap ring from mainshaft, using suitable tool.





18. Remove the mainshaft rear bearing from mainshaft, using suitable tool.
19. Remove retainer from mainshaft.





20. Remove snap ring from mainshaft, using suitable tool.
21. Remove oil pump assembly from mainshaft.





22. Remove snap ring from mainshaft, using suitable tool.
23. Remove clutch gear from mainshaft.





24. Remove snap ring from L-H shift rod assembly, using suitable tool.
25. Remove 2-4 sleeve and 2-4 shift fork assembly from mainshaft.





26. Remove drive chain together with sprocket and front drive shaft from front case.
27. Remove spacer and needle bearing from mainshaft.
28. Remove mainshaft from sun gear assembly.
29. Remove L-H shift rod assembly and control shift rod assembly from front case.
30. Remove L-H sleeve together with L-H shift fork assembly from planetary carrier assembly.





31. Remove snap ring from sun gear.

CAUTION: Do not damage the sun gear or input bearing.





32. Press the sun gear assembly and planetary carrier assembly from front case, using Tool.
Tool number: KV38100200 (- )





33. Remove snap ring from front case.





34. Remove internal gear from front case.





35. Remove snap ring from front case.





36. Remove the input bearing from front case, using Tool.
Tool number: KV38100200 ( - )





37. Remove baffle plate from front case.
38. Remove the breather tube from front case.