Part 1
Transfer Assembly: Disassembly and AssemblyCOMPONENTS
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.
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 the front oil seal from the front case using Tool.
Tool number ST33290001 (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.
Do not damage rear case.
11) Remove the rear oil seal from the rear case using Tool.
Tool number ST33290001 (J-34286)
CAUTION:
Do not damage rear case or mainshaft.
12) Remove the input oil seal from the front case using suitable tool.
CAUTION:
Do not damage 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 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.
16) Remove the spacer from the control shift rod.
CAUTION:
Do not drop spacer.
17) Remove the snap ring from the mainshaft using suitable tool.
18) Remove the mainshaft rear bearing from the mainshaft using suitable tool.
19) Remove the retainer from the mainshaft.
20) Remove the snap ring from the mainshaft using suitable tool.
21) Remove the oil pump assembly from the mainshaft.
22) Remove the snap ring from the mainshaft using suitable tool.
23) Remove the clutch gear from the mainshaft.
24) Remove the snap ring from the L-H shift rod assembly using suitable tool.
25) Remove the 2-4 sleeve and 2-4 shift fork assembly from the mainshaft.
26) Remove the drive chain together with the sprocket and front drive shaft from the front case.
27) Remove the mainshaft from the sun gear assembly.
28) Remove the L-H shift rod assembly and control shift rod assembly from the front case.
29) Remove the L-H sleeve together with the L-H shift fork from the planetary carrier assembly.
30) Remove the snap ring from the sun gear.
CAUTION:
Do not damage sun gear or input bearing.
31) Press the sun gear assembly and planetary carrier assembly from the front case using Tool.
Tool number :KV38100200 ( - )
32) Remove the snap ring from the front case.
33) Remove the internal gear from the front case.
34) Remove the snap ring from the front case.
35) Remove the input bearing from the front case using Tool.
Tool number :KV38100200 ( - )
36) Remove the baffle plate from the front case.
37) 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.
