Transfer Assembly
DISASSEMBLY
1. REMOVE VEHICLE SPEED SENSOR ASSEMBLY
a. Remove the bolt and vehicle speed sensor assembly.
Torque: 11 Nm (115 kgf-cm, 8 ft. lbs.)
b. Remove the O-ring from the vehicle speed sensor assembly.
HINT: At the time of reassembly, install a new O-ring.
c. Remove the clip and vehicle speed sensor driven gear.
2. M/T (w/Diff. lock, or/and ABS) and A/T:
REMOVE TRANSFER L4 POSITION SWITCH WITH GASKET
Torque: 37 Nm (380 kgf-cm, 27 ft. lbs.)
HINT: At the time of reassembly, install a new gasket.
3. REMOVE TRANSFER 4WD POSITION SWITCH WITH GASKET
Torque: 37 Nm (380 kgf-cm, 27 ft. lbs.)
HINT: At the time of reassembly, install a new gasket.
4. A/T:
REMOVE TRANSFER NEUTRAL POSITION SWITCH WITH GASKET
Torque: 37 Nm (380 kgf-cm, 27 ft. lbs.)
HINT: At the time of reassembly, install a new gasket.
5. M/T:
REMOVE 2 PLUGS AND GASKETS OF FRONT CASK
Torque: 37 Nm (380 kgf-cm, 27 ft. lbs.)
HINT: At the time of reassembly, please refer to the following items.
- Install a new gasket.
- The input and output shafts rotate smoothly.
- Shifting can be made smoothly to all positions.
6. REMOVE PROTECTOR
Remove the 4 bolts and protector.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)
7. A/T:
REMOVE SHIFT GEAR HEAD NO.1 AND NO.2
a. Using a pin punch and hammer, drive out the 2 slotted spring pins.
b. Remove the 2 shift gear heads.
8. REMOVE FRONT BEARING RETAINER
a. Remove the 5 bolts.
Torque: 11 Nm (115 kgf-cm, 8 ft. lbs.)
HINT: At the time of reassembly, apply liquid sealer to the bolt threads.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
b. Using a plastic hammer, tap the front bearing retainer and remove it.
HINT: At the time of reassembly, please refer to the following items.
- Remove any FIPG material and be careful not to drop oil on the contacting surfaces of the front bearing retainer.
- Apply FIPG to the front bearing retainer.
FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent
9. M/T:
REMOVE CONTROL RETAINER AND OIL DEFLECTOR
a. Remove the 4 bolts, control retainer, gasket and oil deflector.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)
HINT: At the time of reassembly, install a new gasket.
b. Remove the select return spring from the control retainer.
10. A/T:
REMOVE UPPER COVER AND OIL DEFLECTOR
Remove the 4 bolts, upper cover, 2 gaskets and oil deflector.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)
HINT: At the time of reassembly, install 2 new gaskets.
11. REMOVE FRONT COMPANION FLANGE
a. Using a chisel and hammer, loosen the staked part of the nut.
HINT: At the time of reassembly, stake a new lock nut.
b. Using SST to hold the flange, remove the companion flange lock nut.
SST 09330-00021
Torque: 118 Nm (1,200 kgf- cm, 87 ft. lbs.)
c. Using SST, remove the companion flange.
SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04051, 09957-04010, 09958-04011)
12. REMOVE REAR COMPANION FLANGE
Remove the rear companion flange in the same way as the front companion flange.
HINT: At the time of reassembly, please refer to the following items.
- Front companion flange bolts are thin.
- Rear companion flange bolts are thick.
13. REMOVE EXTENSION HOUSING
a. Remove the 5 bolts.
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)
HINT: At the time of reassembly, apply liquid sealer to the bolt threads.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
b. Using a plastic hammer, tap the extension housing and remove it.
HINT: At the time of reassembly, please refer to the following items.
- Remove any FIPG material and be careful not to drop oil on the contacting surfaces of the extension housing.
- Apply FIPG to the extension housing.
FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent
14. REMOVE VEHICLE SPEED SENSOR DRIVE GEAR
a. Remove the 2 output shaft washers and vehicle speed sensor drive gear.
b. Using a magnetic finger, remove the ball from the rear output shaft.
15. SEPARATE FRONT CASE AND REAR CASE
a. Remove the 12 bolts.
Torque: 28 Nm (285 kgf-cm, 21 ft. lbs.)
b. Using a screwdriver, separate the front case and rear case.
HINT: At the time of reassembly, please refer to the following items.
- Shift the high and low sleeve to low side (rear side) and assemble the front case and rear case.
- Remove any FIPG material and be careful not to drop oil on the contacting surfaces of the rear case.
- Apply FIPG to the rear case.
FIPG: Part No. 08826-00090, THREE BOND 1281 or equivalent
16. REMOVE STRAIGHT SCREW PLUG, SPRING AND LOCKING BALL
a. Using a hexagon wrench, remove the 2 plugs.
Torque: 19 Nm (190 kgf-cm, 14 ft. lbs.)
HINT: At the time of reassembly, apply liquid sealer to the plug threads.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
b. Using a magnetic finger, remove the 2 springs and bails from the both holes.
17. REMOVE FRONT DRIVE FORK SHAFT, SHIFT FORK, SPRING AND STOPPER
a. Mount the rear case in a vise.
NOTICE: Be careful not to damage the sealing surface.
b. Using a pin punch and hammer, drive out the 2 slotted spring pins.
HINT: When the pin is removed from the front drive fork shaft, the shaft will spring loose if the pin punch is removed, so keep the pin punch inserted in the shaft hole.
HINT: At the time of reassembly, please refer to the following items.
- Using a pin punch and hammer, drive in the 2 slotted spring pins.
- When installing the pin in the front drive fork shaft, push the shaft towards the rear case and install the pin while the spring is compressed.
c. Hold the front drive fork shaft in place by hand, when removing the pin punch.
d. Remove the front drive fork shaft, shift fork, spring and stopper.
HINT: At the time of reassembly, please refer to the following items.
- Place the front drive shift fork into the groove of the clutch sleeve.
- Make sure that the shift fork and stopper are installed in the correct direction.
e. Using a magnetic finger, remove the straight pin.
HINT: At the time of reassembly, apply gear oil to the straight pin and insert it into the case hole.
18. REMOVE HIGH AND LOW FORK SHAFT AND SHIFT FORK
HINT: At the time of reassembly, please refer to the following items.
- Place the high and low shift fork into the groove of the clutch sleeve.
- Make sure that the shift fork is installed in the correct direction.
19. REMOVE REAR OUTPUT SHAFT ASSEMBLY, DRIVEN SPROCKET ASSEMBLY AND CHAIN
a. Using a snap ring expander, remove the snap ring.
b. Using a plastic hammer, tap the rear case while with pulling the rear output shaft assembly and driven sprocket assembly.
HINT: At the time of reassembly, please refer to the following item. If necessary, heat the rear case to about 50 - 80°C (122 - 176°F).
c. Remove the chain.
20. M/T:
REMOVE SYNCHRONIZER RING FROM INPUT SHAFT
HINT:
At the time of reassembly, please refer to the following items.
- Apply MP grease to the synchronizer ring.
- Align the synchronizer ring slots with the shifting keys, and install the synchronizer ring on the high and low clutch hub.
21. REMOVE SEPARATOR WITH OIL STRAINER AND MAGNET
Remove the 3 bolts, separator with the oil strainer and magnet.
Torque: 7.5 Nm (80 kgf-cm, 69 inch lbs.)
22. REMOVE OIL PUMP BODY ASSEMBLY
Remove the 3 bolts and oil pump body assembly.
Torque: 7.5 Nm (80 kgf-cm, 69 inch lbs.)
23. REMOVE OIL PUMP DRIVE GEAR
24. REMOVE PLANETARY GEAR ASSEMBLY WITH INPUT SHAFT ASSEMBLY
a. Using a snap ring expander, remove the snap ring.
b. Pull out the planetary gear assembly with the input shaft assembly.
HINT: At the time of reassembly, please refer to the following item. If necessary, heat the front case to about 50 - 80°C (122 - 176°F).
25. REMOVE LOW GEAR SPLINE PIECE
a. Using a screwdriver, remove the snap ring.
HINT: At the time of reassembly, please refer to the following item. Be sure the end gap of the snap ring is not aligned with cutout portion of the planetary carrier.
b. Remove the low gear spline piece.
26. REMOVE NEEDLE ROLLER BEARING FROM INPUT SHAFT ASSEMBLY
HINT: At the time of reassembly, apply gear oil to the needle roller bearing.
27. REMOVE INPUT GEAR STOPPER AND THRUST BEARING
a. Using a snap ring expander, remove the snap ring.
HINT: At the time of reassembly, please refer to the following item. Select a snap ring that allows 0.05 - 0.15 mm (0.0020 - 0.0059 inch) axial play.
b. Remove the input gear stopper, thrust washer and ball.
HINT: At the time of reassembly, apply gear oil to the input gear stopper and thrust washer.
28. REMOVE INPUT SHAFT ASSEMBLY, THRUST BEARING AND RACE
29. REMOVE PLANETARY RING GEAR
a. Using a screwdriver, remove the snap ring.
HINT: At the time of reassembly, please refer to the following item. Be sure the end gap of the snap ring is not aligned with the upper side of the case.
b. Remove the head screw plug, spring and pin.
Torque: 19 Nm (190 kgf-cm, 14 ft. lbs.)
HINT: At the time of reassembly, apply liquid sealer to the plug threads.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
c. Remove the planetary ring gear.
HINT: At the time of reassembly, please refer to the following item. Make sure that the ring gear is installed in the correct direction.
30. INSPECT SWITCH
Check that continuity exists between terminals. If operation is not as specified, replace the switch.
REASSEMBLY
Reassembly is in the reverse order of disassembly.
HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly.