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AIR BREATHER HOSE
TF-43
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Revision: 2006 January2006 M35/M45
AIR BREATHER HOSEPFP:31098
Removal and InstallationNDS000E3
Refer to the figure for air breather hose removal and installation information.
CAUTION:
Make sure there are no pinched or restricted areas on the air breather hose caused by bending or
winding when installing it.
Be sure to insert air breather hose to transfer tube (metal connector) until hose end reaches the
tube's base and another hose end reaches the tube bend R portion of A/T fluid charging pipe.
SDIA2408E
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TF-44
TRANSFER ASSEMBLY
Revision: 2006 January2006 M35/M45
TRANSFER ASSEMBLYPFP:33100
Removal and InstallationNDS000E4
REMOVAL
1. Remove exhaust front tube with power tool. Refer to EX-3, "EXHAUST SYSTEM" .
2. Remove front and rear propeller shaft. Refer to PR-4, "
FRONT PROPELLER SHAFT" and PR-6, "REAR
PROPELLER SHAFT" .
3. Disconnect transfer assembly harness connector and separate harness from transfer assembly.
4. Remove air breather hose. Refer to TF-43, "
AIR BREATHER HOSE" .
5. Remove control rod. Refer to AT-226, "
Control Rod Removal and Installation" .
6. Support transfer assembly and transmission assembly with a jack.
7. Remove rear engine mounting member and engine mounting insulator with power tool. Refer to EM-113,
"ENGINE ASSEMBLY" .
8. Lower jack to the position where the top transfer mounting bolts
can be removed.
9. Remove transfer mounting bolts with power tool and separate
transfer from transmission.
CAUTION:
Secure transfer assembly and transmission assembly to a
jack.
INSTALLATION
Note the following, and install in the reverse order of removal.
When installing the transfer to the transmission, install the
mounting bolts following the standard below.
After the installation, check the fluid level, fluid leakage and the
A/T positions. Refer to TF-9, "
Inspection" ,AT- 2 2 7 , "Adjustment
of A/T Position" .
PDIA0560J
Bolt No. 1234
Quantity 4321
Bolt length “ ” mm (in)75 (2.95) 45 (1.77) 40 (1.57) 30 (1.18)
Tightening torque
Nꞏm (kg-m, ft-lb)37 (3.8, 27)
SDIA2284E
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TF-52
TRANSFER ASSEMBLY
Revision: 2006 January2006 M35/M45
ASSEMBLY
Front Drive Shaft and Drive Chain
1. Install front drive shaft front bearing, using the drift.
2. Install front drive shaft rear bearing, using the 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
Page 5518 of 5621
TRANSFER ASSEMBLY
TF-53
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Revision: 2006 January2006 M35/M45
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 the drift.
CAUTION:
Apply ATF to inside of rear bearing.
PDIA0273E
SDIA1602E
PDIA0274E
Tool number : KV38104010 ( — )
PDIA0275E
Page 5519 of 5621
TF-54
TRANSFER ASSEMBLY
Revision: 2006 January2006 M35/M45
4. Install snap ring to rear case.
CAUTION:
Do not reuse snap ring.
5. Install mainshaft assembly to rear case, using the 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
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TRANSFER ASSEMBLY
TF-55
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Revision: 2006 January2006 M35/M45
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 the 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 5521 of 5621
TF-56
TRANSFER ASSEMBLY
Revision: 2006 January2006 M35/M45
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
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Revision: 2006 January2006 M35/M45
20. Install rear oil seal to rear case, using the drifts.
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 the 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 the 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