Rear Shield Cover Replacement

Rear Shield Cover Replacement


Special Tools
* KM-6155 Guide Pins
* SA9105E /MKM-883-1A Engine Support Fixture (3-Bar)



Removal Procedure

Caution: Refer to Battery Disconnect Caution (Battery Disconnect Caution) .
1. Remove the battery tray. Refer to Battery Tray Replacement (Service and Repair) .
2. Remove the upper engine cover, if equipped.
3. Remove the gearbox cover.




4. Remove the reversing lamp switch (1).
Disconnect the wiring harness plug, reversing lamp switch.
5. Remove the front frame. Refer to Front Frame Replacement (Replacement) (Front Frame Replacement (Replacement))Front Frame Replacement (Removal) (Front Frame Replacement (Removal)) .




6. Remove the left engine damping block.

* Remove from the left engine damping block bracket.
* Remove the 3 bolts (1).


Important: Do not damage the wiring harnesses and attaching parts.


7. Lower the engine and transmission SA9105E /MKM-883-1A approximately 5 cm.
8. Remove the front left wheel.

Important: When dismantling the end shield (1) it is essential to use KM-6155 (2) as otherwise the shaft seal ring of the central release will be damaged.


9. Remove the end shield cover.





Important: Be careful of the guide sleeves, magnet (3) and spacer washer (4) for axle reverse idler gear.


10. Screw the KM-6155 into the threaded bores.
11. Remove the end shield.
Remove the 4 bolts (arrows).

Important: Replace damaged components.


12. Check all parts for damage.
13. Clean the sealing surfaces.



Installation Procedure

1. Install a new end shield gasket to the transmission with roller bearing grease.





Notice: Refer to Fastener Notice (Fastener Notice) .


Important:
* Check that the magnet (1) and friction washer (2), are correctly seated.

* Use new bolts.



2. Install the end shield (4).
Carefully insert the end shield into the transmission housing.

Tighten the 4 new bolts to 22 N.m (16 lb ft).

3. Remove KM-6155 (3)
4. Install the end shield cover.
5. Install the left front wheel.

Tighten the left front wheel to 110 N.m (81 lb ft).

6. Lift the engine and transmission with SA9105E /MKM-883-1A.




7. Install the left engine damping block.

* Attach to the left support for engine damping block.


Tighten the 3 bolts to 55 N.m (41 lb ft).


8. Install the front frame. Refer to Front Frame Replacement (Replacement) (Front Frame Replacement (Replacement))Front Frame Replacement (Removal) (Front Frame Replacement (Removal)) .




9. Install the reversing lamp switch.

Tighten the reversing lamp switch to 20 N.m (15 lb ft).


* Using new seal ring.
* Connect the wiring harness plug for the reversing lamp switch.

10. Attach the gearbox cover to the transmission.
11. Install the upper engine cover, if present.

Tighten to 7 N.m (62 lb in).

12. Install the batter tray. Refer to Battery Tray Replacement (Service and Repair) .
13. Inspect the transmission fluid level. Refer to Front Wheel Drive Shaft Seal Replacement (Front Wheel Drive Shaft Seal Replacement) .
14. For reprogramming procedures, refer to Control Module References (Programming and Relearning) .