Disassembly And Assembly

TRANSFER ASSEMBLY

Disassembly and Assembly


COMPONENTS






















DISASSEMBLY

1.Remove the drain plug and filler plug.





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

CAUTION:
Do not reuse O-ring.





4.Remove the self-lock nut from the companion flange using suitable tool.





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 the front oil seal from the front case using Tool.
Tool number: ST-33290001 (J-34286)

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





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





9.Remove the wait detection switch (gray) from the rear case.
10.Remove the dust cover from the rear case using suitable tool.

CAUTION:
Do not damage rear case.
11.Remove the oil cover from the dust cover.





12.Remove the rear oil seal from the rear case using Tool.
Tool number: ST-33290001 (J-34286)

CAUTION:
Do not damage rear case or mainshaft.





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

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





14.Remove the retainer bolts and gasket.

CAUTION:
Do not reuse gasket.





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





16.Separate the front case from the rear case. Then remove the rear case by prying it up using suitable tool.

CAUTION:
Do not damage the mating surface.
17.Remove the spacer from the control shift rod.

CAUTION:
Do not drop spacer.





18.Remove the snap ring from the mainshaft using suitable tool.

CAUTION:
Do not reuse snap ring.





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





21.Remove the snap ring from the mainshaft using suitable tool.

CAUTION:
Do not reuse snap ring.
22.Remove the oil pump assembly from the mainshaft.





23.Remove the snap ring from the mainshaft using suitable tool.

CAUTION:
Do not reuse snap ring.
24.Remove the clutch gear from the mainshaft.





25.Remove the snap ring from the L-H shift rod assembly using suitable tool.

CAUTION:
Do not reuse snap ring.
26.Remove the 2-4 sleeve and 2-4 shift fork assembly from the mainshaft.





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





31.Remove the snap ring from the sun gear.

CAUTION:
- Do not reuse snap ring.
- Do not damage sun gear or input bearing.





32.Press the sun gear assembly and planetary carrier assembly from the front case using Tool.
Tool number: KV-38100200 (-)





33.Remove the snap ring from the front case.

CAUTION:
Do not reuse snap ring.





34.Remove the internal gear from the front case.





35.Remove the snap ring from the front case.

CAUTION:
Do not reuse snap ring.





36.Remove the input bearing from the front case using Tool.
Tool number: KV-38100200 (-)





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

INSPECTION AFTER DISASSEMBLY

Case





Check the contact surfaces of the shift rod and bearing for wear and damage. If any is found, replace with a new one.
Sleeve





Check the items below. If necessary, replace them with new ones.
- Damage and excessive wear of the contact surfaces of the sprocket, mainshaft and sleeve.
- Sleeve must move smoothly.
Gear, Shaft and Drive Chain





Check the items below. If necessary, replace them with new ones.
- Damage, peeling, uneven wear and bending of the shaft.
- Excessive wear, damage and peeling of the gear.
Bearing





Check the bearing for damage and rough rotation. If necessary, replace it with a new one.

ASSEMBLY






1.Install the breather tube.

CAUTION:
Install breather tube in the direction shown.





2.Install the baffle plate to the front case. Tighten the bolt to the specified torque. .

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





3.Install the input bearing to the front case using Tool.
Tool number: ST-30720000 (J-25405)





4.Install the new snap ring to the front case.

CAUTION:
Do not reuse snap ring.





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





6.Install the new snap ring to the front case.

CAUTION:
Do not reuse snap ring.





7.Install the planetary carrier assembly and sun gear assembly to the front case using Tool.
Tool number: KV-38100200 (-)





8.Install the new snap ring to the sun gear.

CAUTION:
- Do not reuse snap ring.
- Do not damage sun gear.





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





10.Install the control shift rod assembly to the front case.

CAUTION:
Set pin of L-H shift fork assembly into the groove of drum cam.
11.Turn the control shift rod assembly fully counterclockwise.





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

CAUTION:
Set pin of L-H shift rod assembly into the groove of drum cam.
13.Install the mainshaft to the sun gear assembly.





14.Install the drive chain to the front drive shaft and sprocket.

CAUTION:
Install with the Identification mark of drive chain on the side of the rear bearing of front drive shaft.





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





16.Install the 2-4 sleeve and 2-4 shift fork assembly to the 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.





17.Install the new snap ring to the L-H shift rod assembly using suitable tool.

CAUTION:
Do not reuse snap ring.
18.Install the clutch gear to the mainshaft.





19.Install the new snap ring to the mainshaft using suitable tool.

CAUTION:
Do not reuse snap ring.
20.Install the oil pump assembly to the mainshaft.





21.Install the new snap ring to the mainshaft using suitable tool.

CAUTION:
Do not reuse snap ring.





22.Install the retainer to the mainshaft.

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





23.Install the mainshaft rear bearing to the mainshaft using Tool.
Tool number: KV-32102700 (-)

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





24.Install the new snap ring to the mainshaft using suitable tool.

CAUTION:
Do not reuse snap ring.
25.Install the spacer to the control shift rod.





26.Apply liquid gasket to the mating surface of the front case.
-Use Genuine Anaerobic Liquid Gasket or equivalent. Recommended Chemical Products And Sealants.

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

27.Install the rear case to the front case.





28.Tighten the bolts to the specified torque. .

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





29.Install the retainer bolts with new gasket. Tighten the bolts to the specified torque. .

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





30.Apply petroleum jelly to the circumference of the new oil seal, and install it to the front case using Tools.
Tool number
(A): ST30720000 (J-25405)
(B): KV-40104830 (-)

Dimension (A): 4.0 - 4.6 mm (0.157 - 0.181 in)

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





31.Install the new rear oil seal until it is flush with the end face of the rear case using Tool.
Tool number: KV-38100500 (-)

CAUTION:
- Do not reuse oil seal.
- Apply petroleum jelly to oil seal.
32.Install the oil cover until it reaches the end face of new dust cover.





33.Apply petroleum jelly to the circumference of the new dust cover (1). Position the new dust cover as shown.

CAUTION:
- Do not reuse dust cover.
- Position the protrusions at the position shown.
- (2): Rear case assembly
- (A): Protrusions





34.Install the new dust cover to the rear case using Tool.
Tool number: KV-40105310 (-)

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





35.Apply sealant to the threads of the wait detection switch (gray).
Then install it to the rear case and tighten to the specified torque. .
-Use Genuine Silicone RTV or equivalent. Recommended Chemical Products And Sealants.

CAUTION:
Remove old sealant and oil adhering to threads.





36.Apply sealant to the threads of the 4LO switch (gray with green paint) and ATP switch (black). Then install them to the front case and tighten to the specified torque. .
-Use Genuine Silicone RTV or equivalent. Recommended Chemical Products And Sealants.

CAUTION:
Remove old sealant and oil adhering to threads.





37.Install the new front oil seal until it is flush with the end face of the front case using Tool.
Tool number: KV-38100500 (-)

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.Install the new companion flange self-lock nut. Tighten to the specified torque using suitable tool. .

CAUTION:
Do not reuse self-lock nut.





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

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





41.Install the transfer control device to the rear case.
a.Turn the control shift rod fully counterclockwise using a suitable tool, and then put a mark on the control shift rod.





b.Align the transfer control device shaft cutout with the mark on the control shift rod, and install it.
NOTE:
Turn the transfer control device when the transfer control device connection does not match.





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

CAUTION:
Do not reuse gaskets.