Page 2977 of 3061
TRANSFER ASSEMBLY
TF-155
< SERVICE INFORMATION >
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25. Install the return spring assembly into the clutch hub.
26. Install the press flange by aligning the notches to the clutch hub
as shown.
27. Press the press flange to install the new snap ring into snap ring
groove on mainshaft using Tools.
CAUTION:
Do not reuse snap ring.
28. Install the new snap ring to the mainshaft using suitable tool.
CAUTION:
Do not reuse snap ring.
29. Apply ATF to the thrust needle bearing and install it on the press
flange.
SMT911C
SDIA2194E
Tool number A: ST22452000 (J-34335)
B: ST30911000 ( — )
C: KV31103300 ( — )
SDIA2111E
SDIA2112E
SDIA2109E
Page 2978 of 3061
TF-156
< SERVICE INFORMATION >
TRANSFER ASSEMBLY
30. Install the new snap ring to the main shaft.
CAUTION:
Do not reuse snap ring.
31. Install the mainshaft rear bearing to the center case using Tool.
32. Press the mainshaft assembly into the center case using Tools.
33. Install the C-rings to the mainshaft.
34. Set the washer holder on the mainshaft, and secure it with a
new snap ring using suitable tool.
CAUTION:
Do not reuse snap ring.
SDIA2195E
Tool number : ST15310000 (J-25640-B)
SDIA2196E
Tool number A: ST30911000 ( — )
B: ST33052000 ( — )
SDIA2197E
SDIA2201E
SDIA2104E
Page 2979 of 3061
TRANSFER ASSEMBLY
TF-157
< SERVICE INFORMATION >
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35. Apply petroleum jelly to the stem bleeder and install it to the cen-
ter case.
36. Apply ATF to the new seal ring and install it to the main oil pump
cover.
CAUTION:
Do not reuse seal ring.
37. Install the inner gear and outer gear in the main oil pump hous-
ing. Then measure the side clearance. Refer to TF-166, "
Inspec-
tion and Adjustment".
38. Install the main oil pump housing, outer gear and inner gear to
the center case.
39. Install the main oil pump cover to the center case, and tighten to
the specified torque. Refer to TF-128, "
Disassembly and
Assembly".
SDIA2780E
SDIA2783E
SDIA2174E
SDIA2188E
SDIA2130E
Page 2980 of 3061

TF-158
< SERVICE INFORMATION >
TRANSFER ASSEMBLY
40. Remove all the sealant from the switch mating area and inside
the center case.
CAUTION:
Remove old sealant adhering to mating surfaces. Also
remove any moisture, oil, or foreign material adhering to
application and mating surfaces.
41. Thread the ATP switch and neutral-4LO switch in one to two
pitches and apply sealant to the threads of the switches. Tighten
to the specified torque. Refer to TF-128, "
Disassembly and
Assembly".
•Use Genuine Silicone RTV or equivalent. Refer to GI-45
.
NOTE:
• Neutral-4LO switch harness connector is gray.
• ATP switch harness connector is black.
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.Tool number A: KV40100621 (J-25273)
B: ST30032000 (J-26010-01)SDIA3435E
SDIA2198E
Tool number A: KV40100621 (J-25273)
B: ST30032000 (J-26010-01)
SDIA2199E
SDIA2200E
Page 2981 of 3061

TRANSFER ASSEMBLY
TF-159
< SERVICE INFORMATION >
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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-128, "
Disassembly
and Assembly".
47. Install the rear case assembly. Refer to TF-128, "
Disassembly
and Assembly".
Front Case
1. Install the carrier bearing to the sun gear using Tools.
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.
SMT988C
Tool number A: ST30911000 ( — )
B: KV31103300 ( — )
SDIA2179E
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
Page 2982 of 3061
TF-160
< SERVICE INFORMATION >
TRANSFER ASSEMBLY
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.
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.
SDIA2180E
SDIA2181E
Tool number : ST30720000 (J-25405)
SDIA2172E
SDIA2171E
WDIA0100E
Page 2983 of 3061

TRANSFER ASSEMBLY
TF-161
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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.
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.Tool number : KV38100500 ( — )
SDIA3383E
Tool number : ST33200000 (J-26082)
SDIA2183E
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
Page 2984 of 3061
TF-162
< SERVICE INFORMATION >
TRANSFER ASSEMBLY
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.
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-45
.
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.
SMT992C
SDIA2140E
WDIA0157E
SDIA2138E