Page 3793 of 3924

PREPARATIONTF-7
< SERVICE INFORMATION >
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Commercial Service ToolINFOID:0000000001327427
ST30611000
(J-25742-1)
Drift bar
a: 350 mm (1.10 in)
b: 25 mm (1.10 in) dia.
c: M12 × 1.5P Removing rear bearing
ST35321000
(—)
Drift
a: 49 mm (1.93 in) dia.
b: 41 mm (1.61 in) dia. Removing rear bearing
Installing mainshaft assembly
ST31214000
(J-25269-B)
Drift
a: 34 mm (1.34 in) dia.
b: 25.5 mm (1.004 in) dia. Removing front drive shaft front bearing
Removing front drive shaft rear bearing
KV38104010
(—)
Drift
a: 67 mm (2.64 in) dia.
b: 49 mm (1.93 in) dia. Installing front drive shaft rear bearing
Installing rear bearing
ST33200000
(J-26082)
Drift
a: 60 mm (2.36 in) dia.
b: 44.5 mm (1.752 in) dia. Installing front drive shaft front bearing
ST30621000
(J-25742-5)
Drift
a: 80 mm (3.15 in) dia.
b: 59 mm (2.32 in) dia. Installing mainshaft bearing
Tool number
(Kent-Moore No.)
Tool name
Description
NT663
ZZA1000D
ZZA0534D
ZZA1000D
ZZA1002D
ZZA1000D
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C
Page 3794 of 3924
TF-8
< SERVICE INFORMATION >
PREPARATION
Tool nameDescription
Puller Removing companion flange
Flange wrench Removing and installing self-lock nut
Puller Removing front drive shaft front bearing
Removing front drive shaft rear bearing
Power tool Loosening bolts and nuts
NT077
NT771
ZZB0823D
PBIC0190E
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C
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NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGTF-9
< SERVICE INFORMATION >
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NOISE, VIBRATION AND HARSHN ESS (NVH) TROUBLESHOOTING
NVH Troubleshooting ChartINFOID:0000000001327428
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
tion. If necessary, repair or replace these parts.
Reference pageTF-10TF-40TF-40TF-40TF-40TF-40
SUSPECTED PARTS
(Possible cause)
TRANSFER FLUID (Level low)
TRANSFER FLUID (Wrong)
TRANSFER FLUID (Level too high)
LIQUID GASKET (Damaged)
OIL SEAL (Worn or damaged)
GEAR (Worn or damaged)
BEARING (Worn or damaged)
TRANSFER CASE (Damaged)
Symptom Noise 1 2 3 3 3
Transfer fluid leakage 4 1 2 2 3
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C
Page 3827 of 3924

TRANSFER ASSEMBLYTF-41
< SERVICE INFORMATION >
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DISASSEMBLY
Front Case and Rear Case
1. Remove drain plug and filler plug.
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. Electric controlled coupling 15. Spacer
16. Snap ring 17. O-ring 18. Oil gutter
19. Drain plug 20. Baffle plate 21. Rear bearing
22. Snap ring 23. Spacer 24. Rear oil seal
25. Companion flange 26. Self-lock nut 27. Breather tube
28. Rear case 29. Harness bracket 30. Retainer
31. Filler plug 32. Gasket 1: Apply Genuine Anaerobic Liquid Gasket or equivalent. Refer to GI-44, "
Recommended Chemical Product and Sealant".
2: Apply Genuine Silicone RTV or equivalent. Refer to GI-44, "
Recommended Chemical Product and Sealant".
Refer to GI-8, "
Component" for symbols not described on the above.
SDIA3608E
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C
Page 3830 of 3924
TF-44
< SERVICE INFORMATION >
TRANSFER ASSEMBLY
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 frontdrive shaft with plastic hammer.
CAUTION:
Be careful not to tap drive chain.
14. Remove oil gutter from rear case.
15. Remove oil cover bolt from rear case. And then, remove oil cover (1).
PDIA0267E
Tool number : KV38100300 (J-25523)
PDIA0256E
PDIA0257E
PDIA0261E
SDIA3609E
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C
Page 3831 of 3924
TRANSFER ASSEMBLYTF-45
< SERVICE INFORMATION >
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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 fr om 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
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C
Page 3832 of 3924

TF-46
< SERVICE INFORMATION >
TRANSFER ASSEMBLY
Mainshaft Assembly
1. Separate front case and rear case, then remove mainshaft assembly. Refer to "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 "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.
INSPECTION
Cases
SDIA1602E
PDIA0257E
Tool number : ST31214000 (J-25269-B)
PDIA0269E
Tool number : ST31214000 (J-25269-B)
PDIA0270E
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C
Page 3833 of 3924
TRANSFER ASSEMBLYTF-47
< SERVICE INFORMATION >
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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 necessa ry, 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.
ASSEMBLY
Front Drive Shaft and Drive Chain
PDIA0293E
PDIA0300E
PDIA0294E
SDIA2365E
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C