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Revision: 2004 November 2004 FX35/FX45
ComponentsADS000RT
1. Front case 2. Front oil seal 3. Main shaft oil seal
4. Main shaft bearing 5. Snap ring (hole) 6. Main shaft
7. Needle bearing 8. Sprocket 9. Bolts
10. Electric controlled coupling 11. Oil cover 12. Spacer
13. Snap ring (shaft) 14. Rear bearing 15. Snap ring (hole)
16. Rear oil seal 17. Spacer 18. Companion flange lock nut
19. Companion flange 20. Baffle plate 21. Rear case
22. Filler plug 23. Oil gutter 24. Seal washer
25. Drain plug 26. Retainer 27. Drive chain
28. Front drive shaft rear bearing 29. Front drive shaft 30. Front drive shaft front bearing
31. Dynamic damper 32. Dynamic damper bracket
SDIA2311E
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Disassembly and AssemblyADS000RU
DISASSEMBLY
Removal Front Case
1. Remove front case fixing bolts.
2. Insert tire lever as shown in the figure, separate front case and
rear case. Then, remove rear case by levering it up with a tire
lever or the like.
CAUTION:
Be careful not to damage the mating surface.
3. Remove the front oil seal and main shaft oil seal, from front
case.
Bolts symbol Quantity Nominal length mm (in)
A 11 42 (1.65)
B 1 162 (6.38)
C 1 97 (3.82)
Torx bolts 1 40 (1.57)
SDIA2296E
SDIA1692E
SDIA1600E
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TF-46
TRANSFER ASSEMBLY
Revision: 2004 November 2004 FX35/FX45
4. Remove snap ring from front case.
5. Remove main shaft bearing from front case.
Rear Case
1. Remove the drive chain and front drive shaft from rear case.
2. Remove companion flange lock nut from main shaft using the
flange wrench.
3. Put matching mark on the end of the main shaft corresponding
to the B position matching mark on the companion flange.
SDIA1601E
SDIA1595E
SDIA1693E
Tool number : KV38108300 (J44195)
SDIA1694E
SDIA1798E
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Revision: 2004 November 2004 FX35/FX45
4. Remove the companion flange from main shaft using a suitable
puller.
5. Remove spacer at the end of companion flange.
CAUTION:
Be careful not to damage oil seal.
6. Remove the oil gutter from rear case.
7. Remove the oil cover bolt from rear case.
8. Remove the retainer from connector.
9. Remove the connector from rear case.
10. Remove the main shaft and electric controlled coupling from
rear case using a press.
SDIA1695E
SDIA1598E
SDIA1596E
SDIA1597E
SDIA1599E
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TF-48
TRANSFER ASSEMBLY
Revision: 2004 November 2004 FX35/FX45
11. Using a puller, remove the rear oil seal from rear case.
12. Remove snap ring from rear case.
CAUTION:
Do not reuse snap ring.
13. Remove the rear bearing from rear case.
14. Remove the baffle plate from rear case.
Front Drive Shaft
1. Remove the front drive shaft front bearing from front drive shaft.
2. Remove the front drive shaft rear bearing from front drive shaft.Tool number : KV381054S0 (J34286)
SDIA1698E
SDIA1699E
SDIA1701E
Tool number : ST33061000 (J8107-2)
SDIA1696E
Tool number : ST35322000 ( — )
SDIA1697E
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TRANSFER ASSEMBLY
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Main Shaft and Electric Controlled Coupling
1. Remove the snap ring from main shaft.
2. Remove the spacer, electric controlled coupling, sprocket and
needle bearing from main shaft.
INSPECTION
Gears
Check the gear faces and shaft for wear, cracks, damage, and seizure.
Bearings
Check for seizure, peeling, wear, corrosion, sticking/abnormal noise/roughness in hand turning, and other
damage.
CAUTION:
When replacing the bearing, always replace the inner race and outer race as a pair.
Front Case and Rear Case
Replace with a new one if found any wear or cracks on the contact sides of the case.
Washers
Check for seizure, damage, and unusual wear.
Oil Seals
Discard old oil seals, replace with new ones.
If wear, deterioration of adherence (sealing force of lips), or damage is detected on the lips, replace them.
Snap Ring
Discard old snap rings, replace with new ones.
Lock Nut
Discard old lock nut, replace with new ones.
ASSEMBLY
Rear Case
1. Install the baffle plate into rear case.
2. Install the main shaft rear bearing into rear case.
SDIA1602E
SDIA1701E
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TF-50
TRANSFER ASSEMBLY
Revision: 2004 November 2004 FX35/FX45
3. Install the snap ring to rear case.
CAUTION:
Do not reuse snap ring.
4. Using a drift, install the rear oil seal to the rear case.
CAUTION:
Discard old oil seals; replace with new ones.
Apply multi-purpose grease onto oil seal lips, and ATF
onto the circumference of the oil seal.
SDIA1699E
Tool number : KV40104830 ( — )
SDIA1703E
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Main Shaft and Electric Controlled Coupling
1. Fixing needle bearing to main shaft with grease.
2. Install the sprocket, electric controlled coupling and spacer to
main shaft.
3. Install the snap ring to main shaft.
CAUTION:
Do not reuse snap ring.
Front Drive Shaft
1. Using a press and drift, install the front drive shaft front bearing
to front drive shaft.
2. Using a press and drift, install the front drive shaft rear bearing
to front drive shaft.
SDIA1725E
SDIA1602E
Tool number : ST30022000 ( — )
SDIA1704E
Tool number : ST30914000 ( — )
SDIA1705E