Page 3233 of 3371
TF-108
TRANSFER OIL FILTER
Revision: August 20072004 QX56
3. Apply ATF to the two new O-rings (1), and install them on the oil
filter (2).
CAUTION:
Do not reuse O-rings.
4. Install the oil filter to the transfer assembly. Tighten the bolts to
the specified torque. Refer to TF-110, "
Transfer Components" .
CAUTION:
Do not damage oil filter.
Attach oil filter and tighten bolts evenly.
5. Check the transfer fluid. Refer to MA-24, "
Checking Transfer
Fluid" .
6. Start the engine for one minute. Then stop the engine and
recheck the transfer fluid.
WDIA0285E
SDIA2136E
Page 3234 of 3371

REMOVAL AND INSTALLATION
TF-109
C
E
F
G
H
I
J
K
L
MA
B
TF
Revision: August 20072004 QX56
REMOVAL AND INSTALLATIONPFP:00000
RemovalEDS0018V
1. Remove A/T undercover using power tools.
2. Remove center exhaust tube and muffler. Refer to EX-3, "
EXHAUST SYSTEM" .
3. Remove front and rear propeller shafts. Refer to PR-5, "
REMOVAL" (front) and PR-9, "REMOVAL"
(rear).
CAUTION:
Be careful not to damage spline, sleeve yoke and rear oil seal when removing the rear propeller
shaft
NOTE:
Insert a plug into rear oil seal after removing rear propeller shaft.
4. Remove A/T mount bolts. Refer to AT-255, "
TRANSMISSION ASSEMBLY" .
5. Position two suitable jacks under A/T and transfer assembly.
6. Remove crossmember. Refer to TF-109, "
REMOVAL AND INSTALLATION" .
WAR NIN G:
Support A/T and transfer assembly using two suitable jacks while removing crossmember.
7. Disconnect the ATP switch, neutral 4LO switch, wait detection switch, transfer motor and transfer control
device electrical connectors.
8. Remove breather hoses from the actuator, transfer rear case and transfer motor.
9. Remove the shift actuator from the extension housing.
10. Remove transfer to A/T bolts.
WAR NIN G:
Support transfer assembly with suitable jack while removing it.
11. Remove transfer assembly.
InstallationEDS0018W
1. Installation is in the reverse order of removal.
Bolt length : 45 mm (1.77 in)
Transfer bolt torque : 36 N·m (3.7 kg-m, 26 ft-lb)
SMT872C
Page 3235 of 3371
TF-110
OVERHAUL
Revision: August 20072004 QX56
OVERHAULPFP:00000
Transfer ComponentsEDS0018X
1. 2-4 sleeve 2. L-H sleeve 3. Snap ring
4. Internal gear 5. Planetary carrier assembly 6. Metal bushing
7. Needle bearing 8. Sun gear 9. Carrier bearing
10. Snap ring 11. Snap ring 12. Mainshaft front bearing
13. Wait detection switch 14. Check plug 15. Check spring
16. Check ball 17. Front case 18. Snap ring
19. Oil seal 20. Shift cross 21. Oil seal
22. Lock pin 23. Shift lever 24. Washer
25. Drain plug 26. Oil seal 27. Companion flange
28. Self-lock nut 29. Main shaft 30. Needle bearing
31. Front bearing 32. Front drive shaft 33. Rear bearing
34. Spacer 35. Drive chain 36. Clutch drum
37. Snap ring 38. Clutch hub 39. Snap ring
40. Retaining plate 41. Driven plate (10 sheet) 42. Drive plate (10 sheet)
43. Return spring assembly 44. Press flange 45. Thrust needle bearing
SDIA2090E
Page 3236 of 3371
OVERHAUL
TF-111
C
E
F
G
H
I
J
K
L
MA
B
TF
Revision: August 20072004 QX56
46. Snap ring 47. Retaining pin 48. L-H fork
49. 2-4 fork 50. Shift fork spring 51. Fork guide
52. Retainer pin 53. Shift rod
1. Dust cover 2. Oil seal 3. Rear case
4. Air breather 5. Seal ring 6. Main oil pump cover
7. Inner gear 8. Outer gear 9. Main oil pump housing
10. D-ring 11. D-ring 12. Clutch piston
13. Thrust needle bearing race 14. Oil strainer 15. O-ring
16. Snap ring 17. Control valve assembly 18. Lip seal (7 pieces)
19. Washer 20. Filler plug 21. Filler stud
22. O-ring 23. Oil filter 24. ATP switch
25 Neutral-4LO switch 26. Oil pressure check plug 27. Harness bracket
28. Stem bleeder 29. Harness bracket 30. Center case
31. Mainshaft rear bearing 32. C-ring 33. Washer holder
34. Snap ring 35. Sub oil pump housing 36. Outer gear
37. Inner gear 38. Sub oil pump cover 39. O-ring
40. Transfer motor 41. Connector bracket
SDIA2091E
Page 3237 of 3371
TF-112
REAR CASE
Revision: August 20072004 QX56
REAR CASEPFP:33102
DisassemblyEDS0018Y
1. Remove rear case bolts.
2. Remove rear case from center case, using suitable tool.
3. Remove the dust cover, using suitable tool.
4. Remove the oil seal, using suitable tool.
CAUTION:
Be careful not to damage the rear case.
5. Remove the air breather.
SDIA2092E
SDIA2093E
SDIA2094E
SDIA2095E
Page 3238 of 3371
CENTER CASE
TF-113
C
E
F
G
H
I
J
K
L
MA
B
TF
Revision: August 20072004 QX56
CENTER CASEPFP:33105
DisassemblyEDS0018Z
1. Remove the rear case. Refer to TF-112, "Disassembly" .
a. Remove neutral-4LO and ATP switches.
b. Remove main oil pump from the center case. Refer to TF-122,
"MAIN OIL PUMP" .
2. Remove the stem bleeder from the bleed hole.
3. Remove self-lock nut from companion flange.
4. Put a matchmark on top of front drive shaft thread. The match-
mark should be in line with the mark on the companion flange.
CAUTION:
Always match to the top of the front drive shaft thread
using paint.
SDIA2096E
SDIA2097E
SDIA2098E
SDIA2214E
Page 3239 of 3371
TF-114
CENTER CASE
Revision: August 20072004 QX56
5. Remove companion flange, using suitable tool.
6. Remove the center case bolts.
7. Remove harness bracket.
8. Remove filler plug and washer.
9. Separate center case from front case, using suitable tool, then
remove center case by prying it up.
CAUTION:
Be careful not to damage the mating surface.
10. Remove snap ring and washer holder from the mainshaft.
SDIA2099E
SDIA2100E
SDIA2101E
SDIA2104E
Page 3240 of 3371
CENTER CASE
TF-115
C
E
F
G
H
I
J
K
L
MA
B
TF
Revision: August 20072004 QX56
11. Remove C-rings from mainshaft bearing, using suitable tool.
FRONT DRIVE SHAFT AND DRIVE CHAIN
1. With front drive shaft held by one hand as shown, remove using
a suitable tool, remove front drive shaft with drive chain.
CAUTION:
Do not tap drive chain with a plastic hammer.
2. Remove the front drive shaft front bearing using Tool.
3. Remove the front drive shaft rear bearing using Tool.
SDIA2105E
SMT900C
To o l n u m b e r
A : ST33052000 ( — )
B : ST30031000 ( — )
SDIA2106E
To o l n u m b e r
A : ST33052000 ( — )
B : ST30031000 ( — )
SDIA2107E