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TRANSFER ASSEMBLY TF-45
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Revision: 2006 July 2007 FX35/FX45
Disassembly and AssemblyNDS000AO
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 4250 of 4366
TF-46
TRANSFER ASSEMBLY
Revision: 2006 July 2007 FX35/FX45
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
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TRANSFER ASSEMBLY TF-47
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TF
Revision: 2006 July 2007 FX35/FX45
7. Remove rear oil seal from rear case, using a 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
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TF-48
TRANSFER ASSEMBLY
Revision: 2006 July 2007 FX35/FX45
11. Remove snap ring from front case.
12. Remove mainshaft bearing from front case, using a drift.
13. Remove drive chain and front drive shaft while tapping front drive shaft with plastic hammer.
CAUTION:
Be careful not to tap drive chain.
14. Remove oil gutter from rear case.
15. Remove oil cover bolt and sensor fixing bolt from rear case. And then, remove oil cover.
PDIA0267E
Tool number : KV38100300 (J-25523)
PDIA0256E
PDIA0257E
PDIA0261E
SDIA2403E
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TRANSFER ASSEMBLY TF-49
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TF
Revision: 2006 July 2007 FX35/FX45
16. Remove retainer from transfer assembly harness connector.
17. Remove transfer assembly harness connector from rear case.
18. Remove O-ring from transfer assembly harness connector.
19. Remove mainshaft assembly from rear case, using a drift.
20. Remove snap ring from rear case.
21. Remove rear bearing from rear case, using a drift.
22. Remove baffle plate from rear case.
23. Remove breather tube from rear case.
SDIA1597E
Tool number : ST33052000 ( — )
PDIA0262E
PDIA0263E
Tool number A: ST30611000 (J-25742-1)
B: ST35321000 ( — )
PDIA0264E
SDIA1701E
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TF-50
TRANSFER ASSEMBLY
Revision: 2006 July 2007 FX35/FX45
Mainshaft Assembly
1. Separate front case and rear case, then remove mainshaft assembly. Refer to TF-46, "Front Case and
Rear Case" .
2. Remove snap ring from mainshaft.
3. Remove spacer from mainshaft.
4. Remove electric controlled coupling and sprocket from main- shaft.
5. Remove needle bearing from mainshaft.
Front Drive Shaft and Drive Chain
1. Separate front case and rear case. Refer to TF-46, "Front Case and Rear Case" .
2. Remove drive chain and front drive shaft while tapping front drive shaft with plastic hammer.
CAUTION:
Be careful not to tap drive chain.
3. Remove front drive shaft front bearing, using drift and puller.
4. Remove front drive shaft rear bearing, using drift and puller.
SDIA1602E
PDIA0257E
Tool number : ST31214000 (J-25269-B)
PDIA0269E
Tool number : ST31214000 (J-25269-B)
PDIA0270E
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TRANSFER ASSEMBLY TF-51
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Revision: 2006 July 2007 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 4256 of 4366
TF-52
TRANSFER ASSEMBLY
Revision: 2006 July 2007 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