Page 3089 of 3171
TF-122
TRANSFER ASSEMBLY
7. Install the planetary carrier assembly and sun gear assembly to
the front case, using Tool.
8. Install the snap ring to the sun gear.
CAUTION:
lDo not reuse snap ring.
lDo not damage sun gear.
9. Set the L-H sleeve together with the L-H shift fork assembly onto
the planetary carrier assembly.
10. Install the control shift rod assembly to the front case.
CAUTION:
Set pin of L-H shift fork assembly into the groove of drum
cam.
11. Turn the control shift rod assembly fully counterclockwise.
12. Install the L-H shift rod assembly through the L-H shift fork
assembly opening to the front case.
CAUTION:
Set pin of L-H shift rod assembly into the groove of drum
cam.
13. Install the mainshaft to the sun gear assembly.Tool number : KV38100200
SDIA2791E
PDIA0099E
SDIA2438E
WDIA0215E
WDIA0216E
Page 3090 of 3171
TRANSFER ASSEMBLY
TF-123
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TF
14. Install the drive chain to the front drive shaft and sprocket.
CAUTION:
Install with the identification mark of drive chain on the side
of the rear bearing of front drive shaft.
15. Install the drive chain together with the front drive shaft and
sprocket to the front case.
16. Install the 2-4 sleeve and 2-4 shift fork assembly to the main-
shaft.
CAUTION:
lInstall with proper orientation of 2-4 sleeve.
lInstall 2-4 shift fork with engaging the grooves of 2-4 shift
fork in the retaining pin of 2-4 shift bracket.
17. Install the snap ring to the L-H shift rod assembly, using suitable
tool.
CAUTION:
Do not reuse snap ring.
18. Install the clutch gear to the mainshaft.
19. Install the snap ring to the mainshaft, using suitable tool.
CAUTION:
Do not reuse snap ring.
20. Install the oil pump assembly to the mainshaft.
PDIA0110E
SDIA2464E
SDIA2467E
SDIA2463E
SDIA2462E
Page 3091 of 3171

TF-124
TRANSFER ASSEMBLY
21. Install the snap ring to the mainshaft, using suitable tool.
CAUTION:
Do not reuse snap ring.
22. Install the retainer to the mainshaft.
CAUTION:
Set the projection of oil pump assembly to the identification
hole, and then align locating hole of retainer to the L-H shift
rod assembly.
23. Install the mainshaft rear bearing to the mainshaft, using Tool.
CAUTION:
Do not push too hard in order to avoid snap rings becoming
dislodged from mainshaft.
24. Install the snap ring to the mainshaft, using suitable tool.
CAUTION:
Do not reuse snap ring.
25. Install the spacer to the control shift rod (A/T models only).
26. Apply recommended sealant to the mating surface of the front
case. Refer toTF-112, "
COMPONENTS".
CAUTION:
Remove old sealant adhering to mating surfaces. Also
remove any moisture, oil, or foreign material adhering to
application and mating surfaces.
27. Install the rear case to the front case.
SDIA2461E
SDIA2468E
Tool number : KV32102700
SDIA2469E
SDIA2430E
SDIA3305E
Page 3092 of 3171

TRANSFER ASSEMBLY
TF-125
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TF
28. Tighten the bolts to the specified torque. Refer toTF-112, "COM-
PONENTS".
CAUTION:
Be sure to install the harness brackets and air breather
hose clamp.
29. Install the retainer bolts with new gaskets. Tighten the bolts to
the specified torque. Refer toTF-112, "
COMPONENTS".
CAUTION:
lDo not reuse gasket.
lTighten them to the specified torque again.
30. Apply petroleum jelly to the circumference of the input oil seal,
and install it to the front case, using Tools.
CAUTION:
lDo not reuse oil seal.
lApply petroleum jelly to oil seal.
31. Install the rear oil seal until it is flush with the end face of the rear
case, using Tool.
CAUTION:
lDo not reuse oil seal.
lApply petroleum jelly to oil seal.
32. Apply petroleum jelly to the circumference of the new dust cover.
Position the dust cover using the identification mark as shown.
CAUTION:
lDo not reuse dust cover.
lPosition the identification mark at the position shown.
SDIA3422E
SDIA2789E
Dimension A : 4.0 - 4.6 mm (0.157 - 0.181 in)
Tool number A: ST30720000
B: KV40104830
SDIA3191E
Tool number : KV38100500
PDIA0115E
SDIA3377E
Page 3093 of 3171

TF-126
TRANSFER ASSEMBLY
33. Install the dust cover to the rear case, using suitable tool.
CAUTION:
lDo not reuse dust cover.
lApply petroleum jelly to dust cover.
34. Install check ball and check spring to rear case (M/T models
only).
35. Apply recommended sealant to thread of check plug, then install
it to rear case and tighten to the specified torque (M/T models
only). Refer toTF-112, "
COMPONENTS".
CAUTION:
Remove old sealant and oil adhering to threads.
36. Apply recommended sealant to the threads of the wait detection
switch(gray).Theninstallittotherearcaseandtightentothe
specified torque. Refer toTF-112, "
COMPONENTS".
CAUTION:
Remove old sealant and oil adhering to threads.
37. Apply recommended sealant to the threads of the 4LO switch
(gray with green paint) and ATP switch (black). Then install them
to the front case and tighten to the specified torque. Refer toTF-
11 2 , "COMPONENTS".
CAUTION:
Remove old sealant and oil adhering to threads.
SDIA3257E
SDIA3380E
SDIA3389E
SDIA3390E
Page 3094 of 3171
TRANSFER ASSEMBLY
TF-127
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TF
38. Install the front oil seal until it is flush with the end face of the
front case, using Tool.
CAUTION:
lDo not reuse oil seal.
lApply petroleum jelly to oil seal.
39. Align the matching mark on the front drive shaft with the mark on
the companion flange, then install the companion flange.
40. Install the companion flange self-lock nut. Tighten to the speci-
fied torque, using Tool. Refer toTF-112, "
COMPONENTS".
CAUTION:
Do not reuse self-lock nut.
41. Install the O-ring to the transfer control device.
CAUTION:
lDo not reuse O-ring.
lApply petroleum jelly to O-ring.
42. Install the transfer control device to the rear case.
a. Turn the control shift rod fully counterclockwise using a flat-
bladed screwdriver, and then put a mark on the control shift rod.Tool number : KV38100500
PDIA0117E
SDIA2779E
Tool number : KV40104000
WDIA0219E
SDIA3378E
PDIA0119E
Page 3095 of 3171
TF-128
TRANSFER ASSEMBLY
b. Align the transfer control device shaft cutout with the mark on
the control shift rod, and install it.
NOTE:
Turn the transfer control device when the transfer control device
connection does not match.
c. Tighten the bolts to the specified torque. Refer toTF-112, "
COM-
PONENTS".
43. Install the drain plug and filler plug with new gaskets to the rear
case. Tighten to the specified torque. Refer toTF-112, "
COM-
PONENTS".
CAUTION:
Do not reuse gaskets.
PDIA0120E
SDIA2212E
Page 3096 of 3171
PLANETARY CARRIER
TF-129
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PLANETARY CARRIERPFP:33113
Disassembly and AssemblyEDS0032Q
DISASSEMBLY
1. Remove the snap ring.
2. Remove the sun gear assembly from the planetary carrier
assembly, using suitable tool.
3. Remove the snap ring from the sun gear assembly, using suit-
able tool.
4. Remove the carrier bearing from the sun gear, using Tools.
5. Remove the needle bearing from the sun gear, using Tools.
SDIA2792E
SDIA2353E
Tool number A: ST35300000
B: ST30021000
SDIA2149E
Tool number : ST33710000
SDIA2354E