Page 3289 of 3419
TF-146
TRANSFER ASSEMBLY
Revision: October 20052005 QX56
DISASSEMBLY
Rear Case
1. Remove the rear case bolts.
2. Remove the rear case from the center case.
3. Remove the dust cover, using suitable tool.
4. Remove the oil seal, using suitable tool.
CAUTION:
Do not damage rear case.
5. Remove the air breather.
SDIA2092E
SDIA2093E
SDIA2094E
SDIA2095E
Page 3290 of 3419
TRANSFER ASSEMBLY
TF-147
C
E
F
G
H
I
J
K
L
MA
B
TF
Revision: October 20052005 QX56
Front Case
1. Remove the rear case assembly. Refer to TF-146, "Rear Case" .
2. Remove the transfer control device. Refer to TF-138, "
Removal and Installation" .
3. Remove the lock pin nut.
4. Remove the lock pin, using suitable tool.
5. Remove the shift lever.
6. Remove the oil seal from the front case, using suitable tool.
CAUTION:
Do not damage front case or shift cross.
7. Remove the check plug, check spring and check ball.
8. Remove the wait detection switch.
9. Remove the self-lock nut from the companion flange, using Tool.
SDIA2150E
SDIA2166E
WDIA0196E
Tool number : KV40104000 ( — )
SDIA2657E
Page 3291 of 3419
TF-148
TRANSFER ASSEMBLY
Revision: October 20052005 QX56
10. 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. Never damage the front drive shaft.
11. Remove the companion flange, using suitable tool.
12. Remove the center case bolts and harness bracket.
13. Remove the filler plug and gasket.
14. 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.
15. Remove the shift rod components together with the 2-4 sleeve
and L-H sleeve.
16. Remove the shift cross from the front case.
SDIA2779E
WDIA0133E
SDIA2100E
SDIA2101E
SDIA2140E
Page 3292 of 3419
TRANSFER ASSEMBLY
TF-149
C
E
F
G
H
I
J
K
L
MA
B
TF
Revision: October 20052005 QX56
17. Remove the 2-4 sleeve and L-H sleeve from the 2-4 fork and L-
H fork respectively.
18. Drive out the retaining pin from the shift rod, using suitable tool.
19. Remove the L-H fork, 2-4 fork, shift fork spring and fork guide
from the shift rod.
20. Remove the oil seal from the front case, using suitable tool.
CAUTION:
Do not damage front case or sun gear.
21. Remove the snap ring from the sun gear.
CAUTION:
Do not damage front case or sun gear.
SMT992C
WDIA0134E
SDIA2142E
SDIA2143E
SDIA2144E
Page 3293 of 3419
TF-150
TRANSFER ASSEMBLY
Revision: October 20052005 QX56
22. Remove the sun gear assembly and planetary carrier assembly
from the front case, using Tool.
23. Remove the snap ring and internal gear, using suitable tool.
24. Remove the oil seal, using suitable tool.
CAUTION:
Do not damage front case.
25. Remove the snap ring from the front case.
26. Remove the mainshaft front bearing from the front case, using
Tool.Tool number : ST35300000 ( — )
SDIA2145E
SMT004D
SDIA2170E
SDIA2171E
Tool number : ST33200000 (J-26082)
SDIA2178E
Page 3294 of 3419
TRANSFER ASSEMBLY
TF-151
C
E
F
G
H
I
J
K
L
MA
B
TF
Revision: October 20052005 QX56
27. Remove the snap ring from the planetary carrier assembly,
using suitable tool.
28. Remove the sun gear assembly from the planetary carrier
assembly.
29. Remove the snap ring from the sun gear, using suitable tool.
30. Remove the carrier bearing from the sun gear, using Tools.
31. Remove the needle bearing from the sun gear, using Tool.
SDIA2146E
SDIA2147E
SDIA2148E
Tool number A: ST35300000 ( — )
B: ST30031000 ( — )
SDIA2149E
Tool number : ST33710000 ( — )
SDIA2354E
Page 3295 of 3419
TF-152
TRANSFER ASSEMBLY
Revision: October 20052005 QX56
32. Remove the metal bushing from the sun gear, using Tools.
Center Case
1. Remove the rear case assembly. Refer to TF-146, "Rear Case" .
2. Remove the front case assembly. Refer to TF-147, "
Front Case" .
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.
4. Remove the front drive shaft front bearing, using Tools.
5. Remove the front drive shaft rear bearing, using Tools.Tool number A: ST33710000 ( — )
B: ST35325000 ( — )
C: ST33290001 (J-34286)
SDIA2168E
SMT900C
Tool number A: ST33052000 ( — )
B: ST30031000 ( — )
SDIA2106E
Tool number A: ST33052000 ( — )
B: ST30031000 ( — )
SDIA2107E
Page 3296 of 3419
TRANSFER ASSEMBLY
TF-153
C
E
F
G
H
I
J
K
L
MA
B
TF
Revision: October 20052005 QX56
6. Remove the neutral-4LO and ATP switches.
7. Remove the bolts and main oil pump.
8. Remove the outer gear and inner gear from the main oil pump
housing.
9. Remove the seal ring from the main oil pump cover.
10. Remove the stem bleeder from the bleed hole.
SDIA2096E
SDIA2130E
SDIA2131E
SDIA2783E
SDIA2780E