Disassembly and Assembly: Disassembly

Rear Case

1. Remove the rear case bolts.
   Fig 1: Locating Rear Case Bolts

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2. Remove the rear case from the center case.
   Fig 2: Removing Rear Case From Center Case Using Tool

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3. Remove the dust cover using suitable tool.
   Fig 3: Removing Dust Cover Using Suitable Tool

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4. Remove the rear oil seal using suitable tool.
   CAUTION: Do not damage rear case.
5. Remove the breather tube.
   Fig 4: Removing Rear Oil Seal Using Suitable Tool

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Front Case

1. Remove the rear case assembly. Refer to "DISASSEMBLY AND ASSEMBLY ".
2. Remove the lock pin nut.
3. Remove the lock pin using suitable tool.
4. Remove the shift lever.
   Fig 5: Removing Lock Pin Using Suitable Tool

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5. Remove the side oil seal from the front case using suitable tool.
   CAUTION: Do not damage front case or shift cross.
   Fig 6: Removing Side Oil Seal Of Front Case Using Suitable Tool

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6. Remove the check plug, check spring and check ball.
7. Remove the wait detection switch.
   Fig 7: Identifying Check Plug, Spring And Ball

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8. Remove the self-lock nut from the companion flange using suitable tool.
   Fig 8: Removing Self-Lock Nut From Companion Flange Using Suitable Tool

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9. Put a matching mark on top of the front drive shaft thread in line with the mark on the companion flange.
   CAUTION: Use paint to make the matching mark on the front drive shaft thread. Do not damage the front drive shaft.
   Fig 9: Identifying Matching Mark Of Front Drive Shaft Thread And Companion Flange

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10. Remove the companion flange using suitable tool.
    Fig 10: Removing Companion Flange Using Suitable Tool

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11. Remove the center case bolts, harness bracket and air breather.
12. Remove the filler plug and gasket.
    Fig 11: Locating Center Case Bolts

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13. Separate the center case from the front case. Then remove the center case from the front case by prying it up using suitable tool.
    CAUTION: Do not damage the mating surfaces.
    Fig 12: Separating Center Case From Front Case

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14. Remove the shift rod components together with the 2-4 sleeve and L-H sleeve.
15. Remove the shift cross from the front case, using shift rod (A).
    Fig 13: Removing/Installing Shift Cross From Front Case Using Shift Rod

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16. Remove the 2-4 sleeve and L-H sleeve from the 2-4 fork and LH fork respectively.
    Fig 14: Identifying Shift Rod, 2-4 And L-H Sleeve And Fork

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17. Drive out the retaining pin from the shift rod using suitable tool.
    Fig 15: Removing Retaining Pin From Shift Rod Using Suitable Tool

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18. Remove the L-H fork, 2-4 fork, shift fork spring and fork guide from the shift rod.
    CAUTION: Do not reuse retaining pin.
    Fig 16: Identifying Fork Guide, Shift Fork Spring, 2-4 Fork And L-H Fork To Shift Rod

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19. Remove the input oil seal from the front case using suitable tool.
    CAUTION: Do not damage front case or sun gear.
    Fig 17: Removing Input Oil Seal From Front Case Using Suitable Tool

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20. Remove the snap ring from the sun gear.
    CAUTION:

    • Do not reuse snap ring.
    • Do not damage front case or sun gear.
      Fig 18: Identifying Snap Ring From Sun Gear Assembly

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21. Remove the sun gear assembly and planetary carrier assembly from the front case using Tool.

    Tool number: ST35300000 (-) 

    Fig 19: Removing Sun Gear Assembly And Planetary Carrier Assembly From Front Case Using Tool

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22. Remove the snap ring and internal gear using suitable tool.
    Fig 20: Removing Snap Ring And Internal Gear Using Suitable Tool

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23. Remove the front oil seal using suitable tool.
    CAUTION: Do not damage front case.
    Fig 21: Removing Front Oil Seal Using Suitable Tool

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24. Remove the snap ring from the front case.
    CAUTION: Do not reuse snap ring.
    Fig 22: Identifying Snap Ring

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25. Remove the input bearing from the front case using Tool.

    Tool number: ST33200000 (J-26082) 

    Fig 23: Removing Input Bearing From Front Case Using Tool

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26. Remove the snap ring from the planetary carrier assembly using suitable tool.
    Fig 24: Removing Snap Ring Using Suitable Tool

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27. Remove the sun gear assembly from the planetary carrier assembly.
    Fig 25: Removing Sun Gear Assembly From Planetary Carrier Assembly

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28. Remove the snap ring from the sun gear assembly using suitable tool.
    CAUTION: Do not reuse snap ring.
    Fig 26: Removing/Installing Snap Ring From Sun Gear Assembly Using Suitable Tool

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29. Remove the carrier bearing from the sun gear using Tools.

    Tool number (A): ST35300000 (-) 

    (B): ST30031000 (-) 

    Fig 27: Removing Carrier Bearing From Sun Gear Using Tools

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30. Remove the needle bearing from the sun gear using Tool.

    Tool number: ST33710000 (-) 

    Fig 28: Removing Needle Bearing On Sun Gear Using Tool

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31. Remove the metal bushing from the sun gear using Tools.

    Tool number (A): ST33710000 (-) 

    (B): ST35325000 (-) 

    (C): ST33290001 (J-34286) 

    Fig 29: Removing Metal Bushing From Sun Gear Using Tool

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Center Case

1. Remove the rear case assembly. Refer to "DISASSEMBLY AND ASSEMBLY ".
2. Remove the front case assembly. Refer to "DISASSEMBLY AND ASSEMBLY ".
3. Hold the front drive shaft with one hand and tap to remove the front drive shaft with the drive chain.
   CAUTION: Do not tap drive chain.
   Fig 30: Removing Front Drive Shaft And Drive Chain

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4. Remove the front drive shaft front bearing using Tools.

   Tool number (A): ST33052000 (-) 

   (B): ST30031000 (-) 

   Fig 31: Removing Front Bearing Using Tools

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5. Remove the front drive shaft rear bearing using suitable tools.

   Tool number (A): ST33052000 (-) 

   (B): ST30031000 (-) 

   Fig 32: Removing Front Drive Shaft Rear Bearing Using Suitable Tools

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6. Remove the neutral-4LO and ATP switches.
   Fig 33: Identifying Neutral-4LO And ATP Switches

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7. Remove the bolts and main oil pump cover.
   Fig 34: Locating Main Oil Pump Cover Bolts

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8. Remove the outer gear, inner gear and main oil pump housing from the center case.
   Fig 35: Identifying Outer Gear, Inner Gear And Main Oil Pump Housing

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9. Remove the seal ring from the main oil pump cover.
   CAUTION: Do not reuse seal ring.
   Fig 36: Identifying Seal Ring Of Main Oil Pump Cover

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10. Remove the stem bleeder from the bleed hole.
    Fig 37: Removing/Installing Remove Stem Bleeder Using Magnet

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11. Remove the snap ring and washer holder from the mainshaft.
    CAUTION: Do not reuse snap ring.
    Fig 38: Removing Snap Ring Of Mainshaft

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12. Remove the C-rings from the mainshaft using suitable tool.
    Fig 39: Removing C-Rings On Mainshaft Using Suitable Tool

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13. Set the center case on the press stand. Remove the mainshaft from the center case.
    Fig 40: Removing Mainshaft From Center Case

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14. Remove the snap ring from the mainshaft using suitable tool.
    Fig 41: Removing Snap Ring From Mainshaft Using Suitable Tool

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15. Remove the thrust needle bearing from the press flange.
    Fig 42: Removing Thrust Needle Bearing From Press Flange

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16. Press the press flange until the snap ring is out of place using Tools.

    Tool number (A): ST22452000 (J-34335) 

    (B): ST30911000 (-) 

    (C): KV31103300 (-) 

    Fig 43: Pressing Flange Using Tool

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17. Remove the snap ring from the mainshaft using suitable tool.
    CAUTION: Do not reuse snap ring.
    Fig 44: Removing Snap Ring From Mainshaft Using Suitable Tool

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18. Remove the press flange from the mainshaft.
    Fig 45: Removing Press Flange From Mainshaft

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19. Remove the return spring assembly from the clutch hub.
    Fig 46: Removing Return Spring Assembly From Clutch Hub

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20. Remove each plate from the clutch drum.
    Fig 47: Removing Plate From Clutch Drum

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21. Remove the snap ring from the mainshaft.
    Fig 48: Identifying Snap Ring And Mainshaft

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22. Remove the mainshaft from the clutch drum and clutch hub using suitable tool.
23. Remove the needle bearing and spacer from the mainshaft.
    Fig 49: Removing Mainshaft From Clutch Drum And Clutch Hub Using Suitable Tool

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24. Remove the snap ring from the clutch hub using suitable tool.
    CAUTION: Do not reuse snap ring.
    Fig 50: Removing/Installing Snap Ring From Clutch Hub Using Suitable Tool

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25. Remove the oil pressure check plug from the oil pressure check port.
    CAUTION: Do not reuse oil pressure check plug.
    Fig 51: Identifying Oil Pressure Check Plug And Center Case

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26. Apply air gradually from the oil pressure check port, and remove the clutch piston assembly from the center case.
    Fig 52: Removing Clutch Piston Assembly From Center Case

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27. Remove the thrust needle bearing race from the clutch piston by hooking a edge into 3 notches of the thrust needle bearing race using suitable tool.
    CAUTION: Do not damage clutch piston or thrust needle bearing race.
    Fig 53: Removing Thrust Needle Bearing Race From Clutch Piston Using Suitable Tool

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28. Remove the two D-rings from the clutch piston.
    CAUTION: Do not reuse D-rings.
    Fig 54: Identifying D-Rings, Clutch Piston And Thrust Needle Bearing Race

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29. Remove the mainshaft rear bearing from the center case using Tool.

    Tool number: KV38100300 (J-25523) 

    Fig 55: Removing Mainshaft Rear Bearing From Center Case Using Tool

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30. Remove the two bolts and oil strainer.
    Fig 56: Locating Oil Strainer Bolts

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31. Remove the two O-rings from the oil strainer.
    CAUTION: Do not reuse O-rings.
    Fig 57: Identifying Oil Strainer And O-Rings

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32. Remove the snap ring. Then push the connector assembly into the center case to remove the control valve assembly.
    Fig 58: Identifying Snap Ring

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33. Remove the control valve assembly bolts.
34. Remove the control valve assembly.
    CAUTION:

    • Do not reuse any part that has been dropped or damaged.
    • Make sure valve is assembled in the proper direction.
    • Do not use a magnet because residual magnetism stays during disassembly.
      Fig 59: Locating Control Valve Assembly Bolts

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35. Remove the lip seals from the center case.
    CAUTION: There are two kinds of lip seals (lip seal of large inner diameter: 5 pieces, lip seal of small inner diameter: 2 pieces). Confirm the position before disassembly.
    Fig 60: Identifying Small And Large Lip Seals Of Center Case

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36. Remove the transfer motor bolts and motor from the center case. Then remove the O-ring from the transfer motor.
    Fig 61: Locating Transfer Motor Bolts

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37. Remove the sub oil pump cover bolts.
    Fig 62: Locating Sub Oil Pump Cover Bolts

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38. Thread two bolts (M4 x 0.8) into the holes of sub oil pump cover as shown, and pull out to remove the sub oil pump assembly.
    Fig 63: Threading Bolts Into Hole Of Sub Oil Pump Assembly

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39. Remove the outer gear and inner gear from the sub oil pump housing.
    Fig 64: Identifying Outer Gear And Inner Gear, Sub Oil Pump Housing And Cover

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40. Remove the oil filter bolts and oil filter.
    CAUTION:

    • Do not damage center case and oil filter.
    • Loosen bolts and detach oil filter evenly.
      Fig 65: Locating Oil Filter Bolts

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41. Remove the O-rings (1) from the oil filter (2).
    CAUTION: Do not reuse O-rings.
    Fig 66: Identifying Oil Filter And O-Rings

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42. Remove the oil filter stud from the oil filter.
43. Remove the O-ring from the oil filter stud.
    CAUTION: Do not reuse O-ring.
    Fig 67: Identifying Oil Filter, Stud And O-Ring

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Control Valve Assembly

1. Disassemble the control valve assembly with the following procedure.
   CAUTION:

   • Do not reuse any part that has been dropped or damaged.
   • Make sure valve is assembled in the proper direction.
   • Do not use a magnet because residual magnetism stays during disassembly.
   1. Remove all the bolts except for the two shown.
      Fig 68: Locating Transfer Assembly Bolts

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   2. Remove the following from the control valve assembly:
      • Clutch pressure solenoid valve
      • Clutch pressure switch
      • 2-4WD shift solenoid valve
      • Line pressure switch
      • Transfer fluid temperature sensor
   3. Remove the O-rings from each solenoid valve, switch and terminal body.
      Fig 69: Identifying Clutch Pressure Solenoid Valve, Switches And Transfer Fluid Temperature Sensor

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   4. Place the control valve with the lower body facing up. Remove the two bolts, and then remove the lower body and separator plate from the upper body.
      CAUTION:

      • Do not reuse separator plate.
      • Do not drop relief balls. Detach lower body carefully.
        Fig 70: Identifying Separator Plate, Lower And Upper Body

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   5. Make sure the reverse balls, relief balls, relief springs, accumulator pistons and valve springs are securely installed as shown, and remove them.
      Fig 71: Identifying Reverse Balls, Relief Balls, Relief Springs, Accumulator Pistons And Valve Springs

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   6. Remove the retainer plates.
      Fig 72: Locating Retainer Plates

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   7. Remove each retainer plate (1), plug (2), control valve (3) and spring (4) from the upper body (5).
      Fig 73: Identifying Upper Body, Control Valves, Springs And Retainer Plate

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