Page 2948 of 3061
TF-126
< SERVICE INFORMATION >
TRANSFER OIL FILTER
TRANSFER OIL FILTER
Removal and InstallationINFOID:0000000003532569
REMOVAL
1. Remove the oil filter bolts and oil filter.
CAUTION:
• Do not damage center case and oil filter.
• Loosen bolts and detach oil filter evenly.
2. Remove the O-rings (1) from the oil filter (2).
3. Remove the oil filter stud from the oil filter.
4. Remove the O-ring from the oil filter stud.
INSTALLATION
1. Apply ATF to the new O-ring, and install it on the oil filter stud.
CAUTION:
Do not reuse O-ring.
2. Install the oil filter stud to the oil filter.
SMT875C
WDIA0285E
SDIA3180E
SDIA3180E
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TRANSFER OIL FILTER
TF-127
< SERVICE INFORMATION >
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3. Apply ATF to the two new O-rings (1), and install them on the oil
filter (2).
CAUTION:
Do not reuse O-rings.
4. Install the oil filter to the transfer assembly. Tighten the bolts to
the specified torque. Refer to TF-128, "
Disassembly and
Assembly".
CAUTION:
• Do not damage oil filter.
• Attach oil filter and tighten bolts evenly.
5. Check the transfer fluid. Refer to TF-11
.
6. Start the engine and let it run for one minute. Then stop the
engine and recheck the transfer fluid. Refer to TF-11
.
WDIA0285E
SDIA2136E
Page 2950 of 3061

TF-128
< SERVICE INFORMATION >
TRANSFER ASSEMBLY
TRANSFER ASSEMBLY
Removal and InstallationINFOID:0000000003532570
REMOVAL
1. Remove the drain plug and gasket. Drain the fluid. Refer to TF-11, "Replacement".
2. Remove the A/T undercover using power tool.
3. Remove the center exhaust tube and main muffler. Refer to EX-3, "
Removal and Installation".
4. Remove the front and rear propeller shafts. Refer to PR-4, "
Removal and Installation" (front), PR-8,
"Removal and Installation" (rear).
CAUTION:
Do not damage spline, sleeve yoke and rear oil seal when removing rear propeller shaft.
NOTE:
Insert a plug into the rear oil seal after removing the rear propeller shaft.
5. Remove the A/T nuts from the A/T crossmember.
6. Position two suitable jacks under the A/T and transfer assembly.
7. Remove the crossmember. Refer to AT-223, "
Removal and Installation (2WD)".
WARNING:
Support A/T and transfer assembly using two suitable jacks while removing crossmember.
8. Disconnect the electrical connectors from the following:
•ATP switch
• Neutral 4LO switch
• Wait detection switch
• Transfer motor
• Transfer control device
• Transfer terminal cord assembly
9. Disconnect each air breather hose from the following. Refer to TF-122, "
Removal and Installation".
• Actuator
• Breather tube (transfer)
• Transfer motor (case connector)
10. Remove the transfer control device from the extension housing.
11. Remove the transfer to A/T and A/T to transfer bolts.
WARNING:
Support transfer assembly with suitable jack while removing it.
12. Remove the transfer assembly.
INSTALLATION
Installation is in the reverse order of removal.
• Tighten the bolts to specification.
• After installation check the transfer fluid level and for fluid leakage.
Refer to TF-11
.
• After filling, start the engine and let it run for one minute. Then stop
the engine and recheck the transfer fluid.
Disassembly and AssemblyINFOID:0000000003532571
COMPONENTS
Bolt length : 45 mm (1.77 in)
Transfer bolt torque : 36 N·m (3.7 kg-m, 27 ft-lb)
SDIA3181E
Page 2951 of 3061

TRANSFER ASSEMBLY
TF-129
< SERVICE INFORMATION >
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1. 2-4 sleeve 2. L-H sleeve 3. Snap ring
4. Internal gear 5. Planetary carrier assembly 6. Metal bushing
7. Needle bearing 8. Sun gear 9. Carrier bearing
10. Snap ring 11. Snap ring 12. Input bearing
13. Wait detection switch 14. Check plug 15. Check spring
16. Check ball 17. Front case 18. Snap ring
19. Input oil seal 20. Shift cross 21. Side oil seal
22. Lock pin 23. Shift lever 24. Gasket
25. Drain plug 26. Front oil seal 27. Companion flange
28. Self-lock nut 29. Mainshaft 30. Needle bearing
31. Front bearing 32. Front drive shaft 33. Rear bearing
34. Spacer 35. Drive chain 36. Clutch drum
37. Snap ring 38. Clutch hub 39. Snap ring
40. Retaining plate 41. Driven plate (10 sheet) 42. Drive plate (10 sheet)
43. Return spring assembly 44. Press flange 45. Thrust needle bearing
46. Snap ring 47. Retaining pin 48. L-H fork
49. 2-4 fork 50. Shift fork spring 51. Fork guide
52. Retainer pin 53. Shift rod
WDIA0194E
Page 2952 of 3061

TF-130
< SERVICE INFORMATION >
TRANSFER ASSEMBLY
DISASSEMBLY
Rear Case
1. Dust cover 2. Rear oil seal 3. Rear case
4. Breather tube 5. Seal ring 6. Main oil pump cover
7. Inner gear 8. Outer gear 9. Main oil pump housing
10. D-ring 11. D-ring 12. Clutch piston
13. Thrust needle bearing race 14. Oil strainer 15. O-ring
16. Snap ring 17. Control valve assembly 18. Lip seal (large 5 pieces)
19. Lip seal (small 2 pieces) 20. Gasket 21. Filler plug
22. Oil filter stud 23. O-ring 24. Oil filter
25 ATP switch 26. Neutral-4LO switch 27. Oil pressure check plug
28. Harness bracket 29. Air breather hose clamp 30. Stem bleeder
31. Harness bracket 32. Center case 33. Mainshaft rear bearing
34. C-ring 35. Washer holder 36. Snap ring
37. Sub oil pump housing 38. Outer gear 39. Inner gear
40. Sub oil pump cover 41. O-ring 42. Transfer motor
43. Connector bracket A. Apply Genuine Anaerobic Liquid
Gasket, Three Bond TB1133C or
equivalent.B. Apply Genuine Liquid Gasket, Three
Bond TB1215 or equivalent.
WDIA0302E
Page 2953 of 3061
TRANSFER ASSEMBLY
TF-131
< SERVICE INFORMATION >
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1. Remove the rear case bolts.
2. Remove the rear case from the center case.
3. Remove the dust cover using suitable tool.
4. Remove the rear oil seal using suitable tool.
CAUTION:
Do not damage rear case.
5. Remove the breather tube.
Front Case
1. Remove the rear case assembly. Refer to TF-128, "Disassembly and Assembly".
2. Remove the lock pin nut.
SDIA2092E
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Page 2954 of 3061
TF-132
< SERVICE INFORMATION >
TRANSFER ASSEMBLY
3. Remove the lock pin using suitable tool.
4. Remove the shift lever.
5. Remove the side oil seal from the front case using suitable tool.
CAUTION:
Do not damage front case or shift cross.
6. Remove the check plug, check spring and check ball.
7. Remove the wait detection switch.
8. Remove the self-lock nut from the companion flange using Tool.
9. Put a matching mark on top of the front drive shaft thread in line
with the mark on the companion flange.
CAUTION:
Use paint to make the matching mark on the front drive
shaft thread. Never damage the front drive shaft.
SDIA2150E
SDIA3381E
WDIA0196E
Tool number : KV40104000 ( — )
SDIA2841E
SDIA2779E
Page 2956 of 3061
TF-134
< SERVICE INFORMATION >
TRANSFER ASSEMBLY
17. Drive out the retaining pin from the shift rod using suitable tool.
18. Remove the L-H fork, 2-4 fork, shift fork spring and fork guide
from the shift rod.
19. Remove the input oil seal from the front case using suitable tool.
CAUTION:
Do not damage front case or sun gear.
20. Remove the snap ring from the sun gear.
CAUTION:
Do not damage front case or sun gear.
21. Remove the sun gear assembly and planetary carrier assembly
from the front case using Tool.
WDIA0134E
SDIA2142E
SDIA3382E
SDIA2144E
Tool number : ST35300000 ( — )
SDIA2145E