Part 1
Transfer Assembly: Disassembly and Assembly
Part 1
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.
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 check plug, check shift spring and check ball (M/T models only).
11) Remove the dust cover from the rear case, using suitable tool.
CAUTION:
Do not damage rear case.
12) Remove oil cover from the dust cover.
13) Remove the rear oil seal from the rear case, using Tool.
CAUTION:
Do not damage rear case or mainshaft.
14) Remove the input oil seal from the front case, using suitable tool.
CAUTION:
Do not damage front case, sun gear or input bearing.
15) Remove the retainer bolts and gaskets.
16) Remove the rear case bolts, harness bracket and air breather hose clamp from the rear case.
17) 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.
18) Remove the spacer from the control shift rod (A/T models only).
CAUTION:
Do not drop spacer.
19) Remove the snap ring from the mainshaft, using suitable tool.
20) Remove the mainshaft rear bearing from the mainshaft, using suitable tool.
21) Remove the retainer from the mainshaft.
22) Remove the snap ring from the mainshaft, using suitable tool.
23) Remove the oil pump assembly from the mainshaft.
24) Remove the snap ring from the mainshaft, using suitable tool.
25) Remove the clutch gear from the mainshaft.
26) Remove the snap ring from the L-H shift rod assembly, using suitable tool.
27) Remove the 2-4 sleeve and 2-4 shift fork assembly from the mainshaft.
28) Remove the drive chain together with the sprocket and front drive shaft from the front case.
29) Remove the mainshaft from the sun gear assembly.
30) Remove the L-H shift rod assembly and control shift rod assembly from the front case.
31) Remove the L-H sleeve together with the L-H shift fork from the planetary carrier assembly.
32) Remove the snap ring from the sun gear.
CAUTION:
Do not damage sun gear or input bearing.
33) Press the sun gear assembly and planetary carrier assembly from the front case, using Tool.
34) Remove the snap ring from the front case.
35) Remove the internal gear from the front case.
36) Remove the snap ring from the front case.
37) Remove the input bearing from the front case, using Tool.
38) Remove the baffle plate from the front case.
39) 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. Refer to [Transfer Assembly: Disassembly and Assembly].
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.
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 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.
8) Install the 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 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 snap ring to the mainshaft, using suitable tool.
CAUTION:
Do not reuse snap ring.