Page 3281 of 3383
TF-176
TRANSFER ASSEMBLY
Revision: November 20092006 QX56
42. Install the front drive shaft rear bearing using Tools.
43. Install the front drive shaft to the front bearing using Tools.
44. Install the drive chain to the front drive shaft and clutch drum.
CAUTION:
Install drive chain by aligning identification marks to the
rear as shown.
45. Tap the front drive shaft while keeping it upright and press-fit the front drive shaft rear bearing.
CAUTION:
Do not tap drive chain.
46. Install the front case assembly. Refer to TF-176, "
Front Case" .
47. Install the rear case assembly. Refer to TF-181, "
Rear Case" .
Front Case
1. Install the carrier bearing to the sun gear using Tools.Tool number A: KV40100621 (J-25273)
B: ST30032000 (J-26010-01)
SDIA2198E
Tool number A: KV40100621 (J-25273)B: ST30032000 (J-26010-01)
SDIA2199E
SDIA2200E
SMT988C
Tool number A: ST30911000 ( — ) B: KV31103300 ( — )
SDIA2179E
Page 3282 of 3383
TRANSFER ASSEMBLYTF-177
CE F
G H
I
J
K L
M A
B
TF
Revision: November 2009 2006 QX56
2. Install the new snap ring to the sun gear assembly using suitable
tool.
CAUTION:
Do not reuse snap ring.
3. Apply ATF to the circumference of the new metal bushing and install it to the sun gear assembly using Tool.
CAUTION:
Do not reuse metal bushing.
Apply ATF to metal bushing before installing.
4. Apply ATF to the new needle bearing and install it to the sun gear assembly using Tool.
CAUTION:
Do not reuse needle bearing.
Apply ATF to needle bearing before installing.
5. Install the sun gear assembly to the planetary carrier assembly.
6. Install the new snap ring to the planetary carrier assembly. CAUTION:
Do not reuse snap ring.
SDIA2148E
Tool number : ST35300000 ( — )
Dimension A : 7.7 - 8.3 mm (0.303 - 0.327 in)
SDIA3189E
Tool number : ST33220000 ( — )
Dimension B : 62.5 - 63.1 mm (2.461 - 2.484 in)
SDIA3190E
SDIA2180E
SDIA2181E
Page 3283 of 3383
TF-178
TRANSFER ASSEMBLY
Revision: November 20092006 QX56
7. Set the input bearing into the front case and install using Tool.
8. Install the new snap ring into the front case.
CAUTION:
Do not reuse snap ring.
9. Install the internal gear with its groove facing the new snap ring into the front case. Then secure it with the new snap ring.
CAUTION:
Do not reuse snap ring.
10. Install new front oil seal until it is seated flush with the end face of the front case using Tool.
CAUTION:
Do not reuse oil seal.
Apply petroleum jelly to front oil seal lip before installing.
11. Install the planetary carrier assembly and sun gear assembly to the front case using Tool.Tool number : ST30720000 (J-25405)
SDIA2172E
SDIA2171E
WDIA0100E
Tool number : KV38100500 ( — )
SDIA3383E
Tool number : ST33200000 (J-26082)
SDIA2183E
Page 3284 of 3383
TRANSFER ASSEMBLYTF-179
CE F
G H
I
J
K L
M A
B
TF
Revision: November 2009 2006 QX56
12. Install the new snap ring to the sun gear assembly.
CAUTION:
Do not reuse snap ring.
13. Apply petroleum jelly to the circumference of the new input oil seal, and install it to the front case using Tools.
CAUTION:
Do not reuse input oil seal.
Apply petroleum jelly to input oil seal.
14. Install the fork guide, shift fork spring, 2-4 fork, and L-H fork to the shift rod, and secure them with new retaining pins.
CAUTION:
Do not reuse retaining pins.
15. Install the 2-4 sleeve and L-H sleeve to each fork.
16. Install the shift cross to the front case.
17. While aligning the L-H sleeve with the planetary carrier, install the shift rod assembly to the front case.
SDIA2144E
Tool number A: ST30720000 (J-25405)
B: ST33200000 (J-26082)
Dimension "A" : 4.0 - 4.6 mm (0.157 - 0.181 mm)
SDIA3191E
SDIA2142E
SMT992C
SDIA2140E
Page 3285 of 3383

TF-180
TRANSFER ASSEMBLY
Revision: November 20092006 QX56
18. Apply liquid gasket to the entire center case mating surface of
the front case assembly as shown.
Use Genuine Anaerobic Liquid Gasket or equivalent.
Refer to GI-46, "
RECOMMENDED CHEMICAL PRODUCTS
AND SEALANTS" .
CAUTION:
Remove all foreign materials such as water, oil and grease
from center case and front case mating surfaces.
19. Install the center case assembly to the front case assembly. CAUTION:
Do not damage mainshaft end.
20. Tap the center case lightly and press-fit the front drive shaft bearing into the front case.
21. Tighten the front case bolts to the specified torque. Refer to TF-
146, "COMPONENTS" .
CAUTION:
Be sure to install harness bracket and air breather hose
clamp.
22. Install the drain plug with a new gasket. CAUTION:
Do not reuse gasket.
23. Align the matching mark on the front drive shaft with the mark on the companion flange, then install the companion flange.
WDIA0157E
SDIA2138E
SDIA2100E
SDIA2779E
Page 3286 of 3383

TRANSFER ASSEMBLYTF-181
CE F
G H
I
J
K L
M A
B
TF
Revision: November 2009 2006 QX56
24. Install the new companion flange self-lock nut. Tighten to the
specified torque using Tool. Refer to TF-146, "
COMPONENTS" .
CAUTION:
Do not reuse self-lock nut.
25. Remove all the sealant from the check plug, switch mating sur- face and front case.
CAUTION:
Remove old sealant adhering to mating surfaces. Also
remove any moisture, oil, or foreign material adhering to
application and mating surfaces.
26. Install the check ball and check spring to the front case. Apply silicone gasket, to the check plug and wait detection switch and
install them to the front case. Tighten to the specified torque.
Refer to TF-146, "
COMPONENTS" .
Use Genuine Silicone RTV or equivalent. Refer to GI-46,
"RECOMMENDED CHEMICAL PRODUCTS AND SEAL-
ANTS" .
NOTE:
Wait detection switch harness connector is black.
27. Install the new oil seal in the front case using Tool.
CAUTION:
Do not reuse oil seal.
Apply petroleum jelly to seal lip before installing.
28. Install the shift lever to the shift cross.
29. Install the lock pin and lock pin nut. Tighten to the specified torque. Refer to TF-146, "
COMPONENTS" .
Rear Case
1. Apply petroleum jelly to the circumference of the new rear oil
seal. Install the new rear oil seal so that it is flush with the case
tip face using Tool.
CAUTION:
Do not reuse oil seal.
Apply petroleum jelly to seal lip before installing.Tool number : KV40104000 ( — )
WDIA0219E
Tool number : ST22360002 (J-25679-01)
WDIA0158E
SDIA2182E
Tool number : ST30720000 (J-25405)
SDIA2204E
Page 3287 of 3383

TF-182
TRANSFER ASSEMBLY
Revision: November 20092006 QX56
2. Apply petroleum jelly to the circumference of the new dust cover.
Position the new dust cover using the identification mark as
shown.
CAUTION:
Do not reuse dust cover.
Position the identification mark at the position shown.
3. Install the dust cover using Tool.
4. Install the breather tube into the rear case.
5. Remove all the sealant from the rear case to center case mating surfaces.
CAUTION:
Remove all foreign materials such as water, oil, and grease
from center case and rear case mating surfaces.
6. Apply liquid gasket to the entire rear case mating surface of the center case.
Use Genuine Anaerobic Liquid Gasket or equivalent.
Refer to GI-46, "
RECOMMENDED CHEMICAL PRODUCTS
AND SEALANTS" .
CAUTION:
Do not to allow Liquid Gasket to enter stem bleeder hole.
7. Install the rear case to the center case. Tighten the bolts to the specified torque. Refer to TF-146, "
COMPONENTS" .
SDIA3436E
Tool number : KV40105310 ( — )
SDIA2205E
SDIA2206E
SDIA2092E
Page 3288 of 3383

SERVICE DATA AND SPECIFICATIONS (SDS)TF-183
CE F
G H
I
J
K L
M A
B
TF
Revision: November 2009 2006 QX56
SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
General SpecificationsEDS003BH
Inspection and AdjustmentEDS003BI
CLEARANCE BETWEEN INNER GEAR AND OUTER GEAR
Unit: mm (in)
CLUTCH
Unit: mm (in)
PINION GEAR END PLAY
Unit: mm (in)
CLEARANCE BETWEEN SHIFT FORK AND SLEEVE
Unit: mm (in)
SELECTIVE PARTS
Sub-oil Pump
Unit: mm (in)
*: Always check with the Parts Department for the latest parts information. Applied model
VK56DE
Transfer model ATX14B
Fluid capacity (Approx.) (US qt, lmp qt) 3.0 (3-1/8, 2-5/8)
Gear ratio High
1.000
Low 2.596
Number of teeth Sun gear
57
Internal gear 91
Front drive sprocket 38
Front drive shaft 38
ItemSpecification
Main oil pump 0.015 - 0.035 (0.0006 - 0.0014)
Sub-oil pump 0.015 - 0.035 (0.0006 - 0.0014)
ItemLimit value
Drive plate 1.4 (0.055)
ItemStandard
Pinion gear end play 0.1 - 0.7 (0.004 - 0.028)
ItemStandard
Shift fork and sleeve Less than 0.36 (0.0142)
Gear thicknessPart number*
Inner gear Outer gear
9.27 - 9.28 (0.3650 - 0.3654) 31346 0W46231347 0W462
9.28 - 9.29 (0.3654 - 0.3657) 31346 0W46131347 0W461
9.29 - 9.30 (0.3657 - 0.3661) 31346 0W46031347 0W460