Assembly

FRONT CASE AND REAR CASE


VK50VE : Assembly

1. Install breather tube to rear case within the angle (A) shown as follows.





Install rear oil seal to rear case with the drifts within the dimension (L) shown as follows.

Angle (A) : 80 - 100°


CAUTION:
Never reuse breather tube.
2. Install baffle plate to rear case.
3. Install rear bearing to rear case.

CAUTION:
Never use tools. Always install by hand.





4. Install snap ring (1) to rear case.

CAUTION:
Never reuse snap ring.





5. Install main shaft assembly to rear case with the drift (A) [SST:
ST35321000 ( -- )].
6. Install O-ring to AWD solenoid harness connector.

CAUTION:
- Never reuse O-ring.
- Apply transfer fluid to O-ring.
7. Install AWD solenoid harness connector into rear case.
8. Install retainer to AWD solenoid harness connector.
9. Hold electric controlled coupling harness (1) with oil cover hold plate (2), install oil cover (3) to rear case (4).

CAUTION:
The harness should be guided by a cut portion.





10. Install transfer fluid temperature sensor (1) to rear case.
11. Set drive chain to front drive shaft.






CAUTION:
Identification mark (A) of drive chain should be in the side of front bearing (1) of front drive shaft.
12. Install drive chain to main shaft, and then install front drive shaft.






CAUTION:
Never use tools. Always install by hand.
13. Install main shaft bearing to front case.

CAUTION:
Never use tools. Always install by hand.
14. Install Oil pump to main shaft.





15. Install spacer (1) and steel ball (2) to main shaft.
16. Install snap ring (1) to main shaft.






CAUTION:
Never reuse snap ring.
17. Install snap ring (1) to front case.






CAUTION:
Never reuse snap ring.
18. Apply liquid gasket (1) to mating surface of rear case.





Use Genuine Anaerobic Liquid Gasket or equivalent. Refer to Recommended Chemical Products and Sealants.

CAUTION:
Remove old sealant adhering to mounting surfaces. Also remove any moisture, oil, or foreign material adhering to application and mounting surfaces.
19. Set front case to rear case.

CAUTION:
Never damage the mating surface transmission side.
20. Tighten front case and rear case fixing bolts.





21. Install spacer to main shaft.

CAUTION:
Apply transfer fluid to spacer.





22. Apply transfer fluid to outside of rear oil seal, and install rear oil seal to rear case with the drifts within the dimension (L) shown as follows.






L : 6.7 - 7.3 mm (0.264 - 0.287 in)

CAUTION:
- Never reuse rear oil seal.
- Apply petroleum jelly to oil seal lip.
- When installing, never incline rear oil seal.





23. Install companion flange while aligning the matching mark (A) of main shaft with the mark (B) of companion flange.
24. Tighten self-lock nut to the specified torque with flange wrench





(A) (commercial service tool).

CAUTION:
Never reuse self-lock nut.





25. Apply transfer fluid to outside of main shaft oil seal, and install main shaft oil seal until it is flush with the end face of front case with the drift (A) [SST: ST30720000 (J-25405)].

CAUTION:
- Never reuse main shaft oil seal.
- Apply petroleum jelly to oil seal lip.
- When installing, never incline main shaft oil seal.





26. Apply transfer fluid to outside of front oil seal, and install front oil seal until it is flush with the end face of front case with the drift
(A) [SST: ST27862000 ( -- )].

CAUTION:
- Never reuse front oil seal.
- Apply petroleum jelly to oil seal lip.
- When installing, never incline front oil seal.
27. Set gasket to drain plug. Install it to rear case.

CAUTION:
Never reuse gasket.
28. Set gasket to filler plug. Install it to rear case.

CAUTION:
- Never reuse gasket.
- After oil is filled, tighten filler plug to specified torque.