Page 5505 of 5621
TF-40
FRONT OIL SEAL
Revision: 2006 January2006 M35/M45
FRONT OIL SEALPFP:38189
Removal and InstallationNDS000E1
REMOVAL
1. Remove the drain plug to drain the transfer fluid. Refer to TF-9, "Replacement" .
2. Remove the front propeller shaft. Refer to PR-4, "
FRONT PROPELLER SHAFT" .
3. Remove front oil seal using a flat-bladed screwdriver.
CAUTION:
Be careful not to damage the front case and front drive
shaft.
INSTALLATION
1. Apply ATF to front oil seal, install it with a drift until the end face
of front case.
CAUTION:
Do not reuse front oil seal.
When installing, do not incline front oil seal.
2. Install front propeller shaft. Refer to PR-4, "
FRONT PROPEL-
LER SHAFT" .
3. Install transfer fluid, check fluid level and for fluid leakage. Refer
to TF-9, "
Inspection" .
SDIA1782E
Tool number : ST27862000 ( — )
SDIA1783E
Page 5506 of 5621
REAR OIL SEAL
TF-41
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Revision: 2006 January2006 M35/M45
REAR OIL SEALPFP:33140
Removal and InstallationNDS000E2
REMOVAL
1. Remove the rear propeller shaft. Refer to PR-6, "REAR PROPELLER SHAFT" .
2. Remove self-lock nut of companion flange using a flange
wrench.
3. Put matching mark on the end of the mainshaft. The mark
should be in line with the mark on the companion flange.
CAUTION:
For matching mark, use paint. Do not damage mainshaft.
4. Remove the companion flange using a puller.
CAUTION:
Be careful not to damage the companion flange.
5. Remove the rear oil seal using the puller.
CAUTION:
Be careful not to damage the rear case.
SDIA2454E
SDIA2378E
SDIA1785E
Tool number : KV381054S0 (J-34286)
SDIA1786E
Page 5507 of 5621
TF-42
REAR OIL SEAL
Revision: 2006 January2006 M35/M45
INSTALLATION
1. Apply ATF to rear oil seal, install it with a drifts.
CAUTION:
Do not reuse rear oil seal.
When installing, do not incline rear oil seal.
2. Align the matching mark of mainshaft with the mark of compan-
ion flange, then install the companion flange.
3. Using a flange wrench, install the self-lock nut of companion
flange and tighten to the specified torque. Refer to TF-45,
"COMPONENTS" .
CAUTION:
Do not reuse self-lock nut.
4. Install the rear propeller shaft. Refer to PR-6, "
REAR PROPEL-
LER SHAFT" .
5. Check fluid level. Refer to TF-9, "
Inspection" . Dimension A : 6.7 - 7.3 mm (0.264 - 0.287 in)
Tool number A: ST30720000 (J-25405)
B: KV40104830 ( — )
PDIA0292E
SDIA2378E
PDIA0245E
Page 5508 of 5621
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
Page 5509 of 5621

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
Page 5510 of 5621
TRANSFER ASSEMBLY
TF-45
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Revision: 2006 January2006 M35/M45
Disassembly and AssemblyNDS000E5
COMPONENTS
1. Drive chain 2. Front drive shaft rear bearing 3. Front drive shaft
4. Front drive shaft front bearing 5. Sprocket 6. Mainshaft
7. Needle bearing 8. Snap ring 9. Mainshaft bearing
10. Front case 11. Front oil seal 12. Mainshaft oil seal
13. Oil cover 14. Temperature sensor 15. Electric controlled coupling
16. Spacer 17. Snap ring 18. O-ring
19. Oil gutter 20. Drain plug 21. Baffle plate
22. Rear bearing 23. Snap ring 24. Spacer
25. Rear oil seal 26. Companion flange 27. Self-lock nut
28. Breather tube 29. Rear case 30. Harness bracket
31. Retainer 32. Filler plug 33. Gasket
PDIA0244E
Page 5511 of 5621
TF-46
TRANSFER ASSEMBLY
Revision: 2006 January2006 M35/M45
DISASSEMBLY
Front Case and Rear Case
1. Remove drain plug and filler plug.
2. Remove mainshaft oil seal from front case, using a flat-bladed
screwdriver.
CAUTION:
Be careful not to damage the front case and mainshaft.
3. Remove front oil seal from front case, using a flat-bladed screw-
driver.
CAUTION:
Be careful not to damage the front case and front drive
shaft.
4. Remove self-lock nut.
5. Put a matching mark on the end of mainshaft. The mark should
be in line with the mark on the companion flange.
CAUTION:
For matching mark, use paint. Do not damage mainshaft.
6. Remove companion flange, using a puller.
CAUTION:
Be careful not to damage the companion flange.
PDIA0253E
PDIA0255E
SDIA2378E
PDIA0258E
Page 5512 of 5621
TRANSFER ASSEMBLY
TF-47
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Revision: 2006 January2006 M35/M45
7. Remove rear oil seal from rear case, using the puller.
CAUTION:
Be careful not to damage the rear case.
8. Remove spacer from mainshaft.
9. Remove front case and rear case fixing bolts, then remove har-
ness bracket.
10. Separate front case and rear case. Then, remove front case by
levering it up with a tire lever or the like.
CAUTION:
Be careful not to damage the mating surface.Tool number : KV381054S0 (J-34286)
PDIA0259E
PDIA0260E
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
SDIA2460E