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TRANSFER ASSEMBLY TF-51
C E F
G H
I
J
K L
M A
B
TF
Revision: 2006 December 2006 FX35/FX45
INSPECTION
Cases
Check items below. If necessary, replace them with new ones.
Contact surfaces of bearing for wear, damage, etc.
Damage and cracks of case.
Bearing
Check items below. If necessary, replace them with new ones.
Damage and rough rotation of bearing.
Shaft
Check items below. If necessary, replace them with new one.
Damage, peeling, dent, uneven wear, bending, etc. of shaft.
Gears and Chain
Check items below. If necessary, replace them with new ones.
Excessive wear, damage, peeling, etc. of gear and chain.
PDIA0293E
PDIA0300E
PDIA0294E
SDIA2365E
Page 4354 of 4462
TF-52
TRANSFER ASSEMBLY
Revision: 2006 December 2006 FX35/FX45
ASSEMBLY
Front Drive Shaft and Drive Chain
1. Install front drive shaft front bearing, using drifts.
2. Install front drive shaft rear bearing, using a drift.
3. Install drive chain to front drive shaft. CAUTION:
Identification mark of drive chain should be in the side of
front bearing of front drive shaft.
4. Install drive chain to mainshaft, and then install tap front drive shaft with plastic hammer. Press-fit rear bearing of front drive
shaft to rear case.
CAUTION:
Be careful not to tap drive chain.
5. Install front case to rear case. Refer to TF-53, "
Front Case and
Rear Case" .
Tool number : ST33200000 (J-26082)
PDIA0276E
Tool number : KV38104010 ( — )
PDIA0277E
PDIA0284E
PDIA0257E
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TRANSFER ASSEMBLY TF-53
C E F
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TF
Revision: 2006 December 2006 FX35/FX45
Mainshaft Assembly
1. Install needle bearing to mainshaft. CAUTION:
Apply ATF to periphery of needle bearing.
2. Install sprocket and electric controlled coupling to mainshaft.
3. Install spacer to main shaft.
4. Install snap ring to mainshaft. CAUTION:
Do not reuse snap ring.
5. Install mainshaft assembly to rear case, then install front case and rear case. Refer to TF-53, "
Front Case and Rear Case" .
Front Case and Rear Case
1. Install breather tube, with plastic hammer.
CAUTION:
Pay attention to the direction of breather tube.
2. Install baffle plate to rear case, and tighten bolt to the specified torque. Refer to TF-45, "
COMPONENTS" .
3. Install rear bearing to rear case, using a drift. CAUTION:
Apply ATF to inside of rear bearing.
PDIA0273E
SDIA1602E
PDIA0274E
Tool number : KV38104010 ( — )
PDIA0275E
Page 4356 of 4462
TF-54
TRANSFER ASSEMBLY
Revision: 2006 December 2006 FX35/FX45
4. Install snap ring to rear case. CAUTION:
Do not reuse snap ring.
5. Install mainshaft assembly to rear case, using a drift. CAUTION:
ATF should be applied to contact surface of mainshaft and
rear bearing.
6. Install O-ring to transfer assembly harness connector. CAUTION:
Do not reuse O-ring.
Apply ATF to O-ring.
7. Install transfer assembly harness connector into rear case.
8. Install retainer to transfer assembly harness connector.
9. Set temperature sensor and tighten bolt to the specified torque. Refer to TF-45, "
COMPONENTS" .
10. Hold electric controlled coupling harness with oil cover hold plate, install oil cover to rear case, and tighten bolt to the speci-
fied torque. Refer to TF-45, "
COMPONENTS" .
CAUTION:
The harness should be guided by a cut portion.
PDIA0263E
Tool number : ST35321000 ( — )
SDIA2368E
SDIA1597E
SDIA2404E
Page 4357 of 4462
TRANSFER ASSEMBLY TF-55
C E F
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TF
Revision: 2006 December 2006 FX35/FX45
11. Install oil gutter to rear case. CAUTION:
The tip of oil gutter should be put into rear case groove.
12. Install drive chain to front drive shaft. CAUTION:
Identification mark of drive chain should be in the side of
front bearing of front drive shaft.
13. Install drive chain to mainshaft, and then install tap front drive shaft with plastic hammer. Press-fit rear bearing of front drive
shaft to rear case.
CAUTION:
Be careful not to tap drive chain.
14. Install mainshaft bearing to front case, using a drift.
15. Install snap ring to front case. CAUTION:
Do not reuse snap ring.
PDIA0261E
PDIA0284E
PDIA0257E
Tool number : ST30621000 (J-25742-5)
PDIA0283E
PDIA0267E
Page 4358 of 4462
TF-56
TRANSFER ASSEMBLY
Revision: 2006 December 2006 FX35/FX45
16. Apply liquid gasket to mating surface of rear case.
Use Genuine Anaerobic Liquid Gasket or equivalent.
Refer to GI-48, "
Recommended Chemical Products and
Sealants" .
CAUTION:
Remove old sealant adhering to mounting surfaces. Also
remove any moisture, oil, or foreign material adhering to
application and mounting surfaces.
17. Set front case to rear case. CAUTION:
Be careful not to damage the mating surface transmission
side.
18. Tighten front case and rear case fixing bolts to the specified torque. Refer to TF-45, "
COMPONENTS" .
19. Install spacer to mainshaft. CAUTION:
Apply ATF to spacer.
SDIA2312E
PDIA0279E
Bolts symbol Quantity Bolt length “ ” mm (in)
A 11 42 (1.65)
B 1 162 (6.38)
C 1 97 (3.82)
TORX bolts 1 40 (1.57)
PDIA0251E
PDIA0260E
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TRANSFER ASSEMBLY TF-57
C E F
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TF
Revision: 2006 December 2006 FX35/FX45
20. Install rear oil seal to rear case, using a drift. CAUTION:
Do not reuse rear oil seal.
Apply ATF to rear oil seal.
When installing, do not incline rear oil seal.
21. Install companion flange while align the matching mark of main- shaft with the mark of companion flange.
22. Tighten self-lock nut to the specified torque, with flange wrench. Refer to TF-45, "
COMPONENTS" .
CAUTION:
Do not reuse self-lock nut.
23. Install mainshaft oil seal until it is flush with end face of front case, using drift.
CAUTION:
Do not reuse mainshaft oil seal.
Apply ATF to mainshaft oil seal.
When installing, do not incline mainshaft oil seal.
24. Install front oil seal until it is flush with end face of front case, using drift.
CAUTION:
Do not reuse front oil seal.
Apply ATF to front oil seal.
When installing, do not incline front oil seal.
25. Apply sealant to threads of drain plug. Then install it to rear case and tighten to the specified torque. Refer to TF-45, "
COMPO-
NENTS" .
Dimension A : 6.7 - 7.3 mm (0.264 - 0.287 in)
Tool number A: ST30720000 (J-25405) B: KV40104830 ( — )
PDIA0281E
SDIA2378E
SDIA2369E
Tool number : ST30720000 (J-25405)
PDIA0282E
Tool number : ST27862000 ( — )
PDIA0287E
Page 4360 of 4462
TF-58
TRANSFER ASSEMBLY
Revision: 2006 December 2006 FX35/FX45
Use Genuine Silicone RTV or equivalent. Refer to GI-48, "Recommended Chemical Products and
Sealants" .
CAUTION:
Remove old sealant and oil adhering to threads.
26. Set gasket to filler plug. Install it to rear case and tighten to the specified torque. Refer to TF-45, "
COM-
PONENTS" .
CAUTION:
Do not reuse gasket.