Disassembly

FRONT CASE AND REAR CASE


Disassembly

1. Remove drain plug and filler plug.





2. Remove mainshaft oil seal from front case with a suitable tool.

CAUTION:
Never damage the front case and mainshaft.





3. Remove front oil seal from front case with a suitable tool.

CAUTION:
Never damage the front case and front drive shaft.
4. Remove self-lock nut.





5. Put a matching mark (A) on the end of mainshaft. The mark should be in line with the mark (B) on the companion flange.

CAUTION:
For matching mark, use paint. Never damage mainshaft.





6. Remove companion flange with a puller (A) (commercial service tool).

CAUTION:
Never damage the companion flange.





7. Remove rear oil seal from rear case with the puller (A) [SST:
KV381054S0 (J-34286)].

CAUTION:
Never damage the rear case.





8. Remove spacer (1) from mainshaft.
9. Remove front case and rear case fixing bolts, then remove harness bracket.














10. Remove front case (1) from rear case by levering it up with a suitable tool.

CAUTION:
Never damage the mating surface.





11. Remove snap ring (1) from front case.





12. Remove mainshaft bearing from front case with the drift (A)
[SST: KV38100300 (J-25523)].





13. Remove drive chain and front drive shaft while tapping front drive shaft with plastic hammer.


CAUTION:
Never tap drive chain.






14. Remove oil gutter (1) from rear case.





15. Remove oil cover bolts from rear case. And then, remove oil cover (1).





16. Remove retainer (1) from AWD solenoid harness connector.
17. Remove AWD solenoid harness connector from rear case.
18. Remove O-ring from AWD solenoid harness connector.





19. Remove mainshaft assembly from rear case with the drift (A)
[SST: ST33052000 ( -- )].





20. Remove snap ring (1) from rear case.





21. Remove rear bearing from rear case with the drifts.





22. Remove baffle plate (1) from rear case.
23. Remove breather tube from rear case.