Page 3249 of 3371
TF-124
CENTER CASE
Revision: August 20072004 QX56
OIL FILTER
1. Remove bolts for oil filter.
2. Remove the oil filter using suitable tool as shown.
3. Remove the O-rings (1) from the oil filter (2).
4. Remove the filter stud from oil filter.
5. Remove O-ring from the filter stud.
SDIA2136E
SDIA2137E
WDIA0285E
PDIA0184E
Page 3250 of 3371
FRONT CASE
TF-125
C
E
F
G
H
I
J
K
L
MA
B
TF
Revision: August 20072004 QX56
FRONT CASEPFP:33107
DisassemblyEDS00190
1. Remove rear case from center case. Refer to TF-112, "Disassembly" .
2. Remove the lock pin nut from the lock pin, using suitable tool.
a. Remove the lock pin.
3. Remove the oil seal from the front case, using suitable tool.
CAUTION:
Be careful not to damage the front case and shift cross.
4. Remove front case from center case.
SHIFT ROD COMPONENTS
1. Remove check plug, then check spring and check ball.
a. Remove wait detection switch.
SDIA2150E
SDIA2166E
SDIA2138E
SDIA2139E
Page 3251 of 3371
TF-126
FRONT CASE
Revision: August 20072004 QX56
2. Remove shift rod components together with 2-4 sleeve and L-H
sleeve.
3. Remove the shift cross from the front case.
4. Remove 2-4 sleeve and L-H sleeve from 2-4 fork and L-H fork
respectively.
5. Drive out retaining pin from shift rod, using suitable pin punch.
6. Remove L-H fork, 2-4 fork, shift fork spring and fork guide from
shift rod.
SDIA2140E
SMT992C
SDIA2141E
SDIA2142E
Page 3252 of 3371
FRONT CASE
TF-127
C
E
F
G
H
I
J
K
L
MA
B
TF
Revision: August 20072004 QX56
PLANETARY CARRIER, SUN GEAR AND INTERNAL GEAR
1. Remove oil seal from the front case, using suitable tool.
CAUTION:
Be careful not to damage the front case and sun gear.
2. Remove the snap ring from the sun gear.
3. Remove the sun gear assembly from the front case, using Tool.
4. Remove snap ring from the planetary carrier assembly, using
suitable tool.
SDIA2143E
SDIA2144E
Tool number : ST35300000 ( — )
SDIA2145E
SDIA2146E
Page 3253 of 3371
TF-128
FRONT CASE
Revision: August 20072004 QX56
5. Remove the sun gear assembly from the planetary carrier
assembly.
6. Remove the snap ring from the sun gear assembly, using suit-
able tool.
NOTE:
Do not reuse snap ring.
7. Remove the carrier bearing from the sun gear, using Tool.
8. Remove the needle bearing from the sun gear, using Tool.
SDIA2147E
SDIA2148E
Tool number
A : ST35300000 ( — )
B : ST30021000 ( — )
SDIA2149E
Tool number : ST33710000 ( — )
SDIA2354E
Page 3254 of 3371
FRONT CASE
TF-129
C
E
F
G
H
I
J
K
L
MA
B
TF
Revision: August 20072004 QX56
9. Remove the metal bushing from the sun gear, using suitable
Tool.
10. Remove snap ring, and remove internal gear.
11. Remove front oil seal, using suitable tool.
CAUTION:
Be careful not to damage the front case.
12. Remove snap ring from the front case.
NOTE:
Do not reuse snap ring.To o l n u m b e r
A : ST33710000 ( — )
B : ST35325000 ( — )
C : ST33290001 (J-34286)
SDIA2168E
SDIA2169E
SMT004D
SDIA2170E
SDIA2171E
Page 3255 of 3371
TF-130
FRONT CASE
Revision: August 20072004 QX56
13. Remove the mainshaft front bearing from the front case, using
Tool.
Tool number : ST33200000 (J-26082)
SDIA2178E
Page 3256 of 3371

FRONT CASE
TF-131
C
E
F
G
H
I
J
K
L
MA
B
TF
Revision: August 20072004 QX56
FRONT CASEPFP:33107
InspectionEDS00191
PLANETARY CARRIER
Measure end play of each pinion gear, and make sure the mea-
surement is within specification shown below. If out of specifica-
tion, replace planetary carrier assembly with new one.
Check working face of each gear, bearing and others for dam-
age, burrs, partial wear, dents and other abnormality. If any is
found, replace planetary carrier assembly with new one.
SUN GEAR
Check if oil passage of sun gear assembly is clogged. For this,
try to pass a 3.6 mm (0.142 in) dia. wire through oil passage as
shown.
Check 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 assembly with new one.
INTERNAL GEAR
Check internal gear teeth for damage, partial wear, dents and
other abnormality. If any is found, replace internal gear with new
one.
SHIFT ROD COMPONENTS
Check working face of shift rod and fork for wear, partial wear,
bending and other abnormality. If any is found, replace with new
one.Pinion gear end play : 0.1 - 0.7 mm (0.004 - 0.028 in)
PDIA0185E
PDIA0186E
SMT008D
SMT009D