Front Case and Rear Case
FRONT CASE AND REAR CASEDLN-53 Exploded View:
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 rive 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.
A: Drift bar [SST: ST3061100 (J-25742-1)]
B: Drift [SST: ST35321000 ( - )]
22. Remove baffle plate (1) from rear case.
23. Remove breather tube from rear case.
Assembly
1. Install breather tube with plastic hammer.
CAUTION: Pay attention to the direction of breather tube.
2. Install baffle plate to rear case.
3. Install rear bearing to rear case with the drift (A) [SST: KV38104010 ( - )].
CAUTION: Apply transfer fluid to inside of rear bearing.
4. Install snap ring (1) to rear case.
CAUTION: Never reuse snap ring.
5. Install mainshaft assembly to rear case with the drift (A) [SST: ST35321000 ( - )].
CAUTION: Transfer fluid should be applied to contact surface of main haft and rear bearing.
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 (1) to AWD solenoid harness connector.
9. Hold electric controlled coupling harness (1) with oil cover hold late (2), install oil cover (3) to rear case (4).
CAUTION: The harness should be guided by a cut portion.
10. Install oil gutter (1) to rear case.
CAUTION: The tip of oil gutter should be put into rear case groove.
11. Install drive chain to front drive shaft.
CAUTION: Identification mark (A) of drive chain should be in the side front bearing (1) of front drive shaft.
12. Install drive chain to mainshaft, and then install tap front drive haft with plastic hammer. Press-fit rear bearing of front drive haft to rear case.
CAUTION: Never tap drive chain.
13. Install mainshaft bearing to front case with the drift (A) [SST: ST30621000 (J-25742-5)].
14. Install snap ring (1) to front case.
CAUTION: Never reuse snap ring.
15. Apply liquid gasket to mating surface of rear case.
Use Genuine Anaerobic Liquid Gasket or equivalent.
CAUTION: Remove old sealant adhering to mounting surfaces. Also remove any moisture, oil, or foreign material adhering to application and mounting surfaces.
16. Set front case to rear case.
CAUTION: Never damage the mating surface transmission side.
17. Tighten front case and rear case fixing bolts.
18. Install spacer (1) to mainshaft.
CAUTION: Apply transfer fluid to spacer.
19. Install rear oil seal to rear case with the drifts within the dimension (L) shown as follows.
A: Drift [SST: ST30720000 (J-25405)]
B: Drift [SST: KV40104830 ( - )]
L: 6.7 - 7.3 mm (0.264 - 0.287 in)
CAUTION:
^ Never reuse rear oil seal.
^ Apply transfer fluid to rear oil seal.
^ When installing, never incline rear oil seal.
20. Install companion flange while aligning the matching mark (A) of mainshaft with the mark (B) of companion flange.
21. Tighten self-lock nut to the specified torque with flange wrench (A) (commercial service tool).
CAUTION: Never reuse self-lock nut.
22. Install mainshaft oil seal until it is flush with end face of front case with the drift (A) [SST: ST30720000 (J-25405)].
CAUTION:
^ Never reuse mainshaft oil seal.
^ Apply transfer fluid to mainshaft oil seal.
^ When installing, never incline mainshaft oil seal.
23. Install front oil seal until it is flush with end face of front case with he drift (A) [SST: ST27862000 ( - )].
CAUTION:
^ Never reuse front oil seal.
^ Apply transfer fluid to front oil seal.
^ When installing, never incline front oil seal.
24. Apply sealant to threads of drain plug. Then, install it to rear case.
Use Genuine Silicone RTV or equivalent.
CAUTION: Remove old sealant and oil adhering to threads.
25. Set gasket to filler plug. Install it to rear case.
CAUTION:
^ Never reuse gasket.
^ After oil is filled, tighten filler plug to specified torque.
Inspection
Check items below. If necessary, replace them with new ones.
CASES
^ Contact surfaces of bearing for wear, damage, etc.
^ Damage and cracks of case.
BEARING
^ Damage and rough rotation of bearing.
SHAFT
^ Damage, peeling, dent, uneven wear, bending, etc. of shaft.
GEARS AND CHAIN
^ Excessive wear, damage, peeling, etc. of gear and chain.