Overhaul

TRANSFER ASSEMBLY


Disassembly and Assembly


COMPONENTS
VQ35HR models










VK45DE models











DISASSEMBLY

Front Case and Rear Case
1. Remove drain plug and filler plug.





2. Remove mainshaft oil seal from front case, using a flat-bladed screwdriver.

CAUTION:
Be careful not to damage the front case and mainshaft.





3. Remove front oil seal from front case, using a flat-bladed screwdriver.

CAUTION:
Be careful not to damage the front case and front drive shaft.
4. Remove self-lock nut.





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

CAUTION:
For matching mark, use paint. Do not damage mainshaft.

NOTE:
The figure shows VQ35HR models.
6. Remove companion flange, using a puller.

CAUTION:
Be careful not to damage the companion flange.





- VQ35HR models





- VK45DE models





7. Remove rear oil seal from rear case, using the puller.

Tool number: KV381054S0 (J-34286)

CAUTION:
Be careful not to damage the rear case.





8. Remove spacer from mainshaft.





9. Remove front case and rear case fixing bolts, then remove harness bracket.










10. Separate front case and rear case. Then, remove front case by levering it up with a tire lever or the like.

CAUTION:
Be careful not to damage the mating surface.





11. Remove snap ring from front case.





12. Remove mainshaft bearing from front case, using the drift.

Tool number: KV38100300 (J-25523)





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

CAUTION:
Be careful not to tap drive chain.





14. Remove oil gutter from rear case.





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





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 from rear case, using the drift.

Tool number: ST33052000 ( - )





20. Remove snap ring from rear case.





21. Remove rear bearing from rear case, using the drifts.

Tool number
A: ST30611000 (J-25742-1)
B: ST35321000 ( - )





22. Remove baffle plate from rear case.
23. Remove breather tube from rear case.

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 mainshaft.
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 the drift and puller.

Tool number: ST31214000 (J-25269-B)





4. Remove front drive shaft rear bearing, using the drift and puller.

Tool number: ST31214000 (J-25269-B)

INSPECTION

Cases





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 necessary, 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





1. Install front drive shaft front bearing, using the drift.

Tool number: ST33200000 (J-26082)





2. Install front drive shaft rear bearing, using the drift.

Tool number: KV38104010 ( - )





3. Install drive chain to front drive shaft.

CAUTION:
Identification mark of drive chain should be in the side of front bearing of front drive shaft.





4. Install drive chain to mainshaft, and then install tap front drive shaft with plastic hammer. Press-fit rear bearing of front drive shaft to rear case.

CAUTION:
Be careful not to tap drive chain.
5. Install front case to rear case. Refer to "Front case and rear case".

Mainshaft Assembly





1. Install needle bearing to mainshaft.

CAUTION:
Apply ATF to periphery of needle bearing.
2. Install sprocket and electric controlled coupling to mainshaft.
3. Install spacer to main shaft.





4. Install snap ring to mainshaft.

CAUTION:
Do not reuse snap ring.
5. Install mainshaft assembly to rear case, then install front case and rear case. Refer to "Front case and rear case".

Front Case and Rear Case





1. Install breather tube, with plastic hammer.

CAUTION:
Pay attention to the direction of breather tube.
2. Install baffle plate to rear case, and tighten bolt to the specified torque. Refer to "COMPONENTS".





3. Install rear bearing to rear case, using the drift.

Tool number: KV38104010 ( - )

CAUTION:
Apply ATF to inside of rear bearing.





4. Install snap ring to rear case.

CAUTION:
Do not reuse snap ring.





5. Install mainshaft assembly to rear case, using the drift.

Tool number: ST35321000 ( - )

CAUTION:
ATF should be applied to contact surface of mainshaft and rear bearing.
6. Install O-ring to transfer assembly harness connector.

CAUTION:
- Do not reuse O-ring.
- Apply ATF to O-ring.
7. Install transfer assembly harness connector into rear case.





8. Install retainer to transfer assembly harness connector.





9. Hold electric controlled coupling harness with oil cover hold plate, install oil cover to rear case, and tighten bolts to the specified torque. Refer to "COMPONENTS".

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





10. Install oil gutter 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 of drive chain should be in the side of front bearing of front drive shaft.





12. Install drive chain to mainshaft, and then install tap front drive shaft with plastic hammer. Press-fit rear bearing of front drive shaft to rear case.

CAUTION:
Be careful not to tap drive chain.





13. Install mainshaft bearing to front case, using the drift.

Tool number: ST30621000 (J-25742-5)





14. Install snap ring to front case.

CAUTION:
Do not reuse snap ring.





15. Apply liquid gasket to mating surface of rear case.
- Use Genuine Anaerobic Liquid Gasket or equivalent. Fluid Type Specifications.

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:
Be careful not to damage the mating surface transmission side.





17. Tighten front case and rear case fixing bolts to the specified torque. Refer to "COMPONENTS".










18. Install spacer to mainshaft.

CAUTION:
Apply ATF to spacer.





19. Install rear oil seal to rear case, using the drifts.

Dimension A: 6.7 - 7.3 mm (0.264 - 0.287 in)
Tool number
A: ST30720000 (J-25405)
B: KV40104830 ( - )

CAUTION:
- Do not reuse rear oil seal.
- Apply ATF to rear oil seal.
- When installing, do not incline rear oil seal.





20. Install companion flange while align the matching mark of mainshaft with the mark of companion flange.

NOTE:
The figure shows VQ35HR models.





21. Tighten self-lock nut to the specified torque, with flange wrench. Refer to "COMPONENTS".

CAUTION:
Do not reuse self-lock nut.

NOTE:
The figure shows VQ35HR models.





22. Install mainshaft oil seal until it is flush with end face of front case, using the drift.

Tool number: ST30720000 (J-25405)

CAUTION:
- Do not reuse mainshaft oil seal.
- Apply ATF to mainshaft oil seal.
- When installing, do not incline mainshaft oil seal.





23. Install front oil seal until it is flush with end face of front case, using the drift.

Tool number: ST27862000 ( - )

CAUTION:
- Do not reuse front oil seal.
- Apply ATF to front oil seal.
- When installing, do not incline front oil seal.
24. Apply sealant to threads of drain plug. Then install it to rear case and tighten to the specified torque. Refer to "COMPONENTS".
- Use Genuine Silicone RTV or equivalent. Fluid Type Specifications.

CAUTION:
Remove old sealant and oil adhering to threads.
25. Set gasket to filler plug. Install it to rear case and tighten to the specified torque. Refer to "COMPONENTS".

CAUTION:
- Do not reuse gasket.
- After oil is filled, tighten filler plug to specified torque.