Page 2369 of 2395
SMT991C
3. Remove shift rod components together with 2-4 sleeve and
L-H sleeve.
SMT992C
4. Remove 2-4 sleeve and L-H sleeve from 2-4 fork and L-H fork
respectively.
SMT993C
5. Drive out roll pin from shift rod.
IDo not reuse roll pin.
SMT994C
6. Remove L-H fork, 2-4 fork, shift fork spring and fork guide from
shift rod.
SMT995C
Planetary Carrier, Sun Gear and Internal GearNBTF0079S021. Remove radial needle bearing from sun gear.
DISASSEMBLY
Front Case (Cont'd)
TF-134
Page 2370 of 2395
SMT996C
2. Remove bolts to detach transfer cover.
IDo not reuse bolts.
SMT997C
3. Remove oil seal from transfer cover.
IDo not reuse oil seal.
SMT998C
4. Remove snap ring from main gear bearing.
IDo not reuse snap ring.
SMT999C
5. Remove sun gear by tapping it lightly.
SMT001D
6. Remove snap ring from sun gear.
IDo not reuse snap ring as it is a selective part.
7. Remove washer from sun gear.
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DISASSEMBLY
Front Case (Cont'd)
TF-135
Page 2371 of 2395
SMT002DA
8. Set an adapter to sun gear as shown in the figure. Remove sun
gear from planetary carrier. Remove main gear bearing, bear-
ing race and thrust needle bearing (front and rear of planetary
carrier) from sun gear.
SMT003D
9. Remove plug bolt, then remove resist spring and pin.
SMT004D
10. Remove snap ring, and remove internal gear.
IDo not reuse snap ring.
SMT005D
11. Remove front oil seal.
IDo not reuse oil seal.
12. Loosen nut of outer lever assembly to pull out cotter pin, and
remove outer lever.
13. Remove inner lever assembly.
DISASSEMBLY
Front Case (Cont'd)
TF-136
Page 2372 of 2395

SMT006D
Front Case
INSPECTIONNBTF0080Planetary CarrierNBTF0080S01IMeasure end play of each pinion gear, and make sure the
measurement is within specification shown below. If out of
specification, replace planetary carrier with new one.
Pinion gear end play:
0.1 - 0.7 mm (0.004 - 0.028 in)
ICheck working face of each gear, bearing and others for
damage, burrs, partial wear, dents and other abnormality. If
any is found, replace planetary carrier with new one.
SMT007D
Sun GearNBTF0080S02ICheck if oil passage of sun gear is clogged. For this, try to pass
a 3.6 mm (0.142 in) dia. wire through oil passage as shown in
the figure.
ICheck sliding/contact surface of each gear, bearing and others
for damage, burrs, partial wear, dents, and other abnormality.
If any is found, replace sun gear with new one.
SMT008D
Internal GearNBTF0080S03ICheck internal gear teeth for damage, partial wear, dents and
other abnormality. If any is found, replace internal gear with
new one.
SMT009D
Shift Rod ComponentsNBTF0080S04ICheck working face of shift rod and fork for wear, partial wear,
bending and other abnormality. If any is found, replace with
new one.
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REPAIR FOR COMPONENT PARTS
Front Case
TF-137
Page 2373 of 2395

SMT010D
IMeasure clearance between shift fork and sleeve. If it is out of
specification, replace it with new one.
Standard value:
Less than 0.36 mm (0.0142 in)
SMT942C
Center Case
INSPECTIONNBTF0081Sub-oil PumpNBTF0081S011. Check inner and outer circumference, tooth face, and side-
face of inner and outer gears for damage or abnormal wear.
2. Measure side clearance between oil pump housing edge and
inner gear/outer gear.
3. Make sure side clearance is within specification. If the mea-
surement is out of specification, replace inner and outer gears
together with new ones as a set.
Specification:
0.015 - 0.035 mm (0.0006 - 0.0014 in)
For inner gear and outer gear, refer to SDS, TF-157.
SMT943C
Main Oil PumpNBTF0081S021. Check inner and outer circumference, tooth face, and side-
face of inner and outer gears for damage or abnormal wear.
2. Measure side clearance between oil pump housing edge and
inner gear/outer gear.
3. Make sure side clearance is within specification. If the mea-
surement is out of specification, replace inner and outer gears
with new ones as a set.
Specification:
0.015 - 0.035 mm (0.0006 - 0.0014 in)
For inner gear and outer gear, refer to SDS, TF-157.
SMT944C
MainshaftNBTF0081S03ICheck surfaces which contact sun gear, clutch drum, clutch
hub, press flange, clutch piston, each bearing, etc. for damage,
peel, partial wear, dents, bending, or other abnormal damage.
If any is found, replace with new one.
REPAIR FOR COMPONENT PARTS
Front Case (Cont'd)
TF-138
Page 2374 of 2395

SMT945C
Control ValveNBTF0081S04ICheck oil filter screen for damage. If any is found, replace with
new one.
SMT946CA
ICheck resistance between terminals of 4WD solenoid valve,
2-4WD shift solenoid valve and transfer fluid temperature sen-
sor.
Resistance:
Refer to ªCOMPONENT INSPECTIONº, TF-111.
SMT947C
ICheck sliding faces of control valves and plugs for abnormal-
ity. If any is found, replace the control valve assembly with new
one.
CAUTION:
Replace control valve body together with clutch return spring
as a set.
Control valve:
Refer to SDS, TF-157.
SMT948C
ICheck each control valve spring for damage or distortion, and
also check its free length, outer diameter and wire diameter. If
any damage or fatigue is found, replace control valve body with
new one.
IReplace control valve body together with clutch return
spring as a set.
Inspection standard:
Refer to SDS, TF-157.
SMT949C
ClutchNBTF0081S05ICheck drive plate and driven plate facings for damage, cracks
or other abnormality. If any, replace with new one.
ICheck the thickness of drive plate and driven plate facings.
Inspection standard:
Refer to SDS, TF-158.
CAUTION:
IMeasure facing thickness at 3 points to take an average.
ICheck all the drive and driven plates.
ICheck return spring for damage or deformation.
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REPAIR FOR COMPONENT PARTS
Center Case (Cont'd)
TF-139
Page 2375 of 2395
SMT950C
ICheck stamped mark shown in the figure. Then, check that
free length, outer diameter and wire diameter are within speci-
fications. If any abnormality is found, replace with new return
spring assembly of the same stamped number.
Inspection standard:
Refer to SDS, TF-158.
REPAIR FOR COMPONENT PARTS
Center Case (Cont'd)
TF-140
Page 2376 of 2395
SMT011D
Front Case
ASSEMBLYNBTF0082Planetary Carrier, Sun Gear and Internal GearNBTF0082S011. Apply ATF to oil seal periphery, and install oil seal so that it is
flush with the end face of front case.
IDo not reuse oil seal.
SMT012D
2. Install internal gear with its groove facing snap ring into front
case. Then secure it with snap ring.
IDo not reuse snap ring.
SMT108D
3. Remove all the liquid gasket on plug bolt and front case. Apply
locking sealant to plug bolt, install it to front case and tighten
it to specified torque.
IWith one crest of plug bolt inserted in the hole, apply liquid
gasket 1215 to the thread.
: 19 - 25 N´m (1.9 - 2.5 kg-m, 14 - 18 ft-lb)
SMT014D
4. Install snap ring to main gear bearing.
IDo not reuse snap rings.
SMT015D
5. Set main gear bearing to front case, then press it.
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ASSEMBLY
Front Case
TF-141