Transfer: Removal & Installation Nissan Armada I

INSTALLATION

Installation is in the reverse order of removal.

1. When installing the transfer control unit, tighten bolts to the specified torque. Transfer control unit bolts: 5.1 N.m (0.52 kg-m, 45 in-lb) CAUTION: Do not connect harness connector to transfer control unit when 4WD shift switch is at 4LO.
2. After the installation, check perform self-diagnosis. Refer to «SELF-DIAGNOSTIC PROCEDURE»(ref-233277-S27103964002006052500000) . If NG, adjust position between transfer assembly and transfer control unit. Refer to «PRECAUTIONS FOR TRANSFER ASSEMBLY AND TRANSFER CONTROL UNIT REPLACEMENT»(ref-233277-S34805648432006052500000) .

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1. Partially drain the transfer fluid. Refer to «DRAINING»(ref-233319-S10712107742006052500000) .
2. Remove the front propeller shaft. Refer to «REMOVAL»(ref-233278-S23417333772006052500000) .
3. Remove the companion flange self-lock nut, using Tool. Tool number: KV40104000 ( - )
4. Put a matching mark on top of the front drive shaft in line with the mark on the companion flange. CAUTION: Use paint to make the matching mark on the front drive shaft. Do not damage the front drive shaft.
5. Remove the companion flange, using suitable tool.
6. Remove the oil seal from the front case, using Tool. Tool number: ST33290001 (J-34286) CAUTION: Do not damage front case.

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1. Install the oil seal until it is flush with the end face of the front case, using Tool. Tool number: KV38100500 ( - ) CAUTION: Do not reuse oil seal. Apply petroleum jelly to oil seal.
2. Align the matching mark of the front drive shaft with the matching mark of the companion flange, then install the companion flange.
3. Install the self-lock nut. Tighten to the specified torque, using Tool. Refer to «COMPONENTS»(ref-233277-S37893901402006052500000) . Tool number: KV40104000 ( - ) CAUTION: Do not reuse self-lock nut.
4. Install the front propeller shaft. Refer to «INSTALLATION»(ref-233278-S13581978012006052500000)
5. Refill the transfer with fluid and check fluid level. Refer to «TRANSFER FLUID»(ref-233277-S10907760842006052500000) .
6. Check the transfer for fluid leakage. Refer to «FLUID LEAKAGE AND FLUID LEVEL»(ref-233319-S42052082812006052500000) .

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1. Partially drain the transfer fluid. Refer to «DRAINING»(ref-233319-S10712107742006052500000) .
2. Remove the rear propeller shaft. Refer to «REMOVAL»(ref-233278-S18609968022006052500000) .
3. Remove the dust cover from the rear case. CAUTION: Do not damage the rear case.
4. Remove the rear oil seal from the rear case, using Tool. CAUTION: Do not damage the rear case. Tool number: ST33290001 (J-34286)

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1. Install the oil seal until it is flush with the end face of the rear case, using Tool. Tool number: ST30720000 (J-25405) CAUTION: Do not reuse oil seal. Apply petroleum jelly to oil seal.
2. Apply petroleum jelly to the circumference of the new dust cover. Position the dust cover using the identification mark as shown. CAUTION: Do not reuse dust cover. Position the identification mark at the position shown.
3. Install the dust cover to the rear case, using Tool. Tool number: KV40105310 ( - ) CAUTION: Do not reuse dust cover. Apply petroleum jelly to dust cover.
4. Install the rear propeller shaft. Refer to «INSTALLATION»(ref-233278-S08330633252006052500000) .
5. Refill the transfer with fluid and check fluid level. Refer to «FILLING»(ref-233319-S13047656632006052500000) .
6. Check the transfer for fluid leakage. Refer to «FLUID LEAKAGE AND FLUID LEVEL»(ref-233319-S42052082812006052500000) .

Scheme 67

1. Remove the front propeller shaft. Refer to «REMOVAL»(ref-233278-S23417333772006052500000) .
2. Remove the companion flange. Refer to «REMOVAL»(ref-233277-S10557556962006052500000) .
3. Remove the transfer control device from the transfer assembly. Refer to «Removal and Installation»(ref-233277-S20748892922006052500000) .
4. Remove the side oil seal. CAUTION: Do not damage shift cross.

Scheme 68

1. Install the side oil seal until it is flush with the end face of case, using Tool. Tool number: ST22360002 (J-25679-01) CAUTION: Do not reuse oil seal. Apply petroleum jelly to oil seal.
2. Install the transfer control device to the transfer assembly. Refer to «Removal and Installation»(ref-233277-S20748892922006052500000) .
3. Install the companion flange. Refer to «Removal and Installation»(ref-233277-S10557556962006052500000) .
4. Install the front propeller shaft. Refer to «REMOVAL AND INSTALLATION»(ref-233278-S16508763452006052500000) .

Removal and Installation

Refer to the figure for transfer control device removal and installation information.

Scheme 69

Refer to the figure for air breather hose removal and installation information.

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1. Disconnect the transfer motor connector.
2. Remove the air breather hose from the transfer motor. Refer to «Removal and Installation»(ref-233277-S22301670702006052500000) .
3. Remove the transfer motor bolts.
4. Remove the transfer motor.

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1. Apply ATF to the O-ring and install it to the transfer motor. CAUTION: Do not reuse O-rings.
2. Fit the double-flat end of the transfer motor shaft into the slot of the sub- oil pump assembly. Then tighten to the specified torque. Refer to «COMPONENTS»(ref-233277-S37893901402006052500000) . CAUTION: Be sure to install connector bracket.
3. Install the air breather hose to the transfer motor. Refer to «Removal and Installation»(ref-233277-S22301670702006052500000) .
4. Connect the transfer motor connector.
5. Check the transfer fluid. Refer to «FILLING»(ref-233319-S13047656632006052500000) .
6. Start the engine for one minute. Then stop the engine and recheck the transfer fluid. Refer to «FLUID LEAKAGE AND FLUID LEVEL»(ref-233319-S42052082812006052500000) .

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1. Remove the oil filter bolts and oil filter. CAUTION: Do not damage center case and oil filter. Loosen bolts and detach oil filter evenly.
2. Remove the O-rings from the oil filter.
3. Remove the oil filter stud from the oil filter.
4. Remove the O-ring from the oil filter stud.

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1. Apply ATF to the O-ring, and install it on the oil filter stud. CAUTION: Do not reuse O-ring.
2. Install the oil filter stud to the oil filter.
3. Apply ATF to the two O-rings, and install them on the oil filter. CAUTION: Do not reuse O-rings.
4. Install the oil filter to the transfer assembly. Tighten the bolts to the specified torque. Refer to «COMPONENTS»(ref-233277-S37893901402006052500000) . CAUTION: Do not damage oil filter. Attach oil filter and tighten bolts evenly.
5. Check the transfer fluid. Refer to «FILLING»(ref-233319-S13047656632006052500000) .
6. Start the engine for one minute. Then stop the engine and recheck the transfer fluid. Refer to «FLUID LEAKAGE AND FLUID LEVEL»(ref-233319-S42052082812006052500000) .

REMOVAL

1. Remove the drain plug and gasket. Drain the fluid. Refer to «DRAINING»(ref-233319-S10712107742006052500000) .
2. Remove the A/T undercover, using power tool.
3. Remove the center exhaust tube and main muffler. Refer to «REMOVAL»(ref-233272-S41515308372006052500000) .
4. Remove the front and rear propeller shafts. Refer to «REMOVAL»(ref-233278-S23417333772006052500000) (front), «REMOVAL»(ref-233278-S18609968022006052500000) (rear). CAUTION: Do not damage spline, sleeve yoke and rear oil seal when removing rear propeller shaft. NOTE: Insert a plug into the rear oil seal after removing the rear propeller shaft.
5. Remove the A/T nuts from the A/T crossmember.
6. Position two suitable jacks under the A/T and transfer assembly.
7. Remove the crossmember. Refer to «COMPONENTS»(ref-233274-S41627018092006091900000) . WARNING: Support A/T and transfer assembly using two suitable jacks while removing crossmember.
8. Disconnect the electrical connectors from the following: ATP switch Neutral 4LO switch Wait detection switch Transfer motor Transfer control device
9. Disconnect the air breather hoses from the following: Transfer control device Transfer rear case Transfer motor
10. Remove the transfer control device from the extension housing.
11. Remove the transfer to A/T and A/T to transfer bolts. WARNING: Support transfer assembly with suitable jack while removing it.
12. Remove the transfer assembly.

Installation is in the reverse order of removal, paying attention to the following

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1. Tighten the bolts to specification. Bolt length: 45 mm (1.77 in) Transfer bolt torque: 36 N.m (3.7 kg-m, 26 ft-lb)
2. Fill the transfer with new fluid. Refer to «FILLING»(ref-233319-S13047656632006052500000) .
3. Check the transfer fluid. Refer to «FLUID LEAKAGE AND FLUID LEVEL»(ref-233319-S42052082812006052500000) .
4. Start the engine for one minute. Then stop the engine and recheck the transfer fluid. Refer to «FLUID LEAKAGE AND FLUID LEVEL»(ref-233319-S42052082812006052500000) .

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1. Remove the rear case bolts.
2. Remove the rear case from the center case.
3. Remove the dust cover, using suitable tool.
4. Remove the oil seal, using suitable tool. CAUTION: Do not damage rear case.
5. Remove the air breather.

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1. Remove the rear case assembly. Refer to «Rear Case»(ref-233277-S27451072092006052500000) .
2. Remove the transfer control device. Refer to «Removal and Installation»(ref-233277-S20748892922006052500000) .
3. Remove the lock pin nut.
4. Remove the lock pin, using suitable tool.
5. Remove the shift lever.
6. Remove the oil seal from the front case, using suitable tool. CAUTION: Do not damage front case or shift cross.
7. Remove the check plug, check spring and check ball.
8. Remove the wait detection switch.
9. Remove the self-lock nut from the companion flange, using Tool. Tool number: KV40104000 ( - )
10. Put a matching mark on top of the front drive shaft thread in line with the mark on the companion flange. CAUTION: Use paint to make the matching mark on the front drive shaft thread. Never damage the front drive shaft.
11. Remove the companion flange, using suitable tool.
12. Remove the center case bolts and harness bracket.
13. Remove the filler plug and gasket.
14. Separate the center case from the front case. Then remove the center case from the front case by prying it up, using suitable tool. CAUTION: Do not damage the mating surfaces.
15. Remove the shift rod components together with the 2-4 sleeve and L-H sleeve.
16. Remove the shift cross from the front case.
17. Remove the 2-4 sleeve and L-H sleeve from the 2-4 fork and L-H fork respectively.
18. Drive out the retaining pin from the shift rod, using suitable tool.
19. Remove the L-H fork, 2-4 fork, shift fork spring and fork guide from the shift rod.
20. Remove the oil seal from the front case, using suitable tool. CAUTION: Do not damage front case or sun gear.
21. Remove the snap ring from the sun gear. CAUTION: Do not damage front case or sun gear.
22. Remove the sun gear assembly and planetary carrier assembly from the front case, using Tool. Tool number: ST35300000 ( - )
23. Remove the snap ring and internal gear, using suitable tool.
24. Remove the oil seal, using suitable tool. CAUTION: Do not damage front case.
25. Remove the snap ring from the front case.
26. Remove the mainshaft front bearing from the front case, using Tool. Tool number: ST33200000 (J-26082)
27. Remove the snap ring from the planetary carrier assembly, using suitable tool.
28. Remove the sun gear assembly from the planetary carrier assembly.
29. Remove the snap ring from the sun gear, using suitable tool.
30. Remove the carrier bearing from the sun gear, using Tools. Tool number A: ST35300000 ( - ) B: ST30031000 ( - )
31. Remove the needle bearing from the sun gear, using Tool. Tool number: ST33710000 ( - )
32. Remove the metal bushing from the sun gear, using Tool. Tool number A: ST33710000 ( - ) B: ST35325000 ( - ) C: ST33290001 (J-34286)

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1. Remove the rear case assembly. Refer to «Rear Case»(ref-233277-S27451072092006052500000) .
2. Remove the front case assembly. Refer to «Front Case»(ref-233277-S31947665642006052500000) .
3. Hold the front drive shaft with one hand and tap to remove the front drive shaft with the drive chain. CAUTION: Do not tap drive chain.
4. Remove the front drive shaft front bearing, using Tool. Tool number A: ST33052000 ( - ) B: ST30031000 ( - )
5. Remove the front drive shaft rear bearing, using Tool. Tool number A: ST33052000 ( - ) B: ST30031000 ( - )
6. Remove the neutral-4LO and ATP switches.
7. Remove the bolts and main oil pump.
8. Remove the outer gear and inner gear from the main oil pump housing.
9. Remove the seal ring from the main oil pump cover.
10. Remove the stem bleeder from the bleed hole.
11. Remove the snap ring and washer holder from the mainshaft.
12. Remove the C-rings from the mainshaft, using suitable tool.
13. Set the center case on the press stand. Remove the mainshaft from the center case.
14. Remove the snap ring from the mainshaft, using suitable tool.
15. Remove the thrust needle bearing from the press flange.
16. Press the flange until the snap ring is out of place, using Tools. Tool number A: ST22452000 (J-34335) B: ST30911000 ( - ) C: KV31103300 ( - )
17. Remove the snap ring from the mainshaft, using suitable tool.
18. Remove the press flange from the mainshaft.
19. Remove the return spring assembly from the clutch hub.
20. Remove each plate from the clutch drum.
21. Remove the snap ring from the mainshaft.
22. Remove the mainshaft from the clutch drum and clutch hub, using suitable tool.
23. Remove the needle bearing and spacer from the mainshaft.
24. Remove the snap ring from the clutch hub, using suitable tool.
25. Remove the oil pressure check plug from the oil pressure check port.
26. Apply air gradually from the oil pressure check port, and remove the clutch piston assembly from the center case.
27. Remove the thrust needle bearing race from the clutch piston by hooking a edge into 3 notches of the thrust needle bearing race, using suitable tool. CAUTION: Do not damage clutch piston or thrust needle bearing race.
28. Remove the two D-rings from the clutch piston.
29. Remove the mainshaft rear bearing from the center case, using Tool. Tool number: KV38100300 (J-25523)
30. Remove the two bolts and oil strainer.
31. Remove the two O-rings from the oil strainer.
32. Remove the snap ring. Then push the connector assembly into the center case to remove the control valve assembly.
33. Remove the control valve assembly bolts.
34. Remove the control valve assembly. CAUTION: Do not reuse any part that has been dropped or damaged. Make sure valve is assembled in the proper direction. Do not use a magnet because residual magnetism stays during disassembly.
35. Remove the lip seals from the center case. CAUTION: There are two kinds of lip seals (lip seal of large inner diameter: 5 pieces, lip seal of small inner diameter: 2 pieces). Confirm the position before disassembly.
36. Disassemble the control valve assembly with the following procedure. CAUTION: Do not reuse any part that has been dropped or damaged. Make sure valve is assembled in the proper direction. Do not use a magnet because residual magnetism stays during disassembly. Remove all the bolts except for the two shown. Remove the following from the control valve assembly: Clutch pressure solenoid valve Clutch pressure switch 2-4WD shift solenoid valve Line pressure switch Transfer fluid temperature sensor Remove the O-rings from each solenoid valve, switch and terminal body. Place the control valve with the lower body facing up. Remove the two bolts, and then remove the lower body and separator plate from the upper body. CAUTION: Do not drop relief balls. Detach lower body carefully. Make sure the reverse balls, relief balls, relief springs, accumulator pistons and valve springs are securely installed as shown, and remove them. Remove the retainer plates. Remove each control valve, spring and plug.
37. Remove the transfer motor bolts and motor from the center case. Then remove the O-ring from the transfer motor.
38. Remove the sub oil pump cover bolts.
39. Thread two bolts (M4 x 0.8) into the holes of sub oil pump cover as shown, and pull out to remove the sub oil pump assembly.
40. Remove the outer gear and inner gear from the sub oil pump housing.
41. Remove the oil filter bolts and oil filter. CAUTION: Do not damage center case and oil filter. Loosen bolts and detach oil filter evenly.
42. Remove the O-rings from the oil filter.
43. Remove the oil filter stud from the oil filter.
44. Remove the O-ring from the oil filter stud.

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1. Check the working face of the shift rod and fork for wear, partial wear, bending and other abnormality. If any is found, replace with a new one.
2. Measure the clearance between the shift fork and sleeve. If it is out of specification, replace it with a new one. Specification: Less than 0.36 mm (0.0142 in)

Scheme 157

1. Measure the end play of each pinion gear. If it is out of specification, replace the planetary carrier assembly with a new one. Pinion gear end play: 0.1 - 0.7 mm (0.004 - 0.028 in)
2. Check the working face of each gear and bearing for damage, burrs, partial wear, dents and other abnormality. If any is found, replace the planetary carrier assembly with a new one.

Scheme 158

1. Check if the oil passage of the sun gear assembly is clogged. For this, try to pass a 3.6 mm (0.142 in) dia. pin through the oil passage as shown.
2. Check the sliding and contact surface of each gear and bearing for damage, burrs, partial wear, dents, and other abnormality. If any is found, replace the sun gear assembly with a new one.

Scheme 159

1. Check the internal gear teeth for damage, partial wear, dents and other abnormality. If any is found, replace the internal gear with a new one.

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1. Check the gear faces and shaft for wear, cracks, damage, and seizure.
2. Check the surfaces which contact the sun gear, clutch drum, clutch hub, press flange, clutch piston and each bearing for damage, peel, partial wear, dents, bending, or other abnormal damage. If any is found, replace with a new one.

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1. Make sure the bearings roll freely and are free from noise, pitting and cracks.

Scheme 162

1. Check the inner and outer circumference, tooth face, and sideface of the inner and outer gears for damage or abnormal wear.
2. Measure the side clearance between the main oil pump housing edge and the inner and outer gears.
3. Make sure the side clearance is within specification. If the measurement is out of specification, replace the inner and outer gears with new ones as a set. Refer to «Main Oil Pump»(ref-233277-S19543649912006052500000) Specification: 0.015 - 0.035 mm (0.0006 - 0.0014 in)

Scheme 163

1. Check the inner and outer circumference, tooth face, and sideface of the inner and outer gears for damage or abnormal wear.
2. Measure the side clearance between the sub oil pump housing edge and the inner and outer gears.
3. Make sure the side clearance is within specification. If the measurement is out of specification, replace the inner and outer gears with new ones as a set. Refer to «Sub-oil Pump»(ref-233277-S02394063282006052500000) . Specification: 0.015 - 0.035 mm (0.0006 - 0.0014 in)

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1. Check resistance between the terminals of the clutch pressure solenoid valve, 2-4WD shift solenoid valve, clutch pressure switch and the transfer fluid temperature sensor. Refer to «2-4WD SOLENOID»(ref-233277-S22536554392006052500000) (clutch pressure solenoid valve), «COMPONENT INSPECTION»(ref-233277-S06834540262006052500000) (2-4WD solenoid valve), «COMPONENT INSPECTION»(ref-233277-S06834540262006052500000) (clutch pressure switch) and «COMPONENT INSPECTION»(ref-233277-S06834540262006052500000) (transfer fluid temperature sensor).
2. Check the sliding faces of the control valves and plugs for abnormality. If any is found, replace the control valve assembly with a new one. Refer to «Control Valve»(ref-233277-S11407189142006052500000) . CAUTION: Replace control valve body together with clutch return spring as a set.
3. Check each control valve spring for damage or distortion. Also check its free length, outer diameter and wire diameter. If any damage or fatigue is found, replace the control valve body with a new one. Refer to «Return Spring»(ref-233277-S31521316062006052500000) . CAUTION: Replace control valve body together with clutch return spring as a set.

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1. Check the drive plate facings and driven plate for damage, cracks or other abnormality. If any abnormalities are found, replace with a new one.
2. Check the thickness of the drive plate facings and driven plate. Refer to «CLUTCH»(ref-233277-S23844973892006052500000) . CAUTION: Measure facing thickness at 3 points to take an average. Check all drive and driven plates. Check return spring for damage or deformation. Do not remove spring from plate.

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1. Check the stamped mark shown. Then, check that the free lengths, (include thickness of plate) are within specifications. If any abnormality is found, replace with a new return spring assembly of the same stamped number. Refer to «Return Spring»(ref-233277-S31521316062006052500000) .

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1. Apply ATF to new O-ring, and install it on the oil filter stud. CAUTION: Do not reuse O-rings.
2. Install the oil filter stud to the oil filter.
3. Apply ATF to the two new O-rings, and install them on the oil filter. CAUTION: Do not reuse O-rings.
4. Install the oil filter to the center case. Tighten the bolts to the specified torque. Refer to «COMPONENTS»(ref-233277-S37893901402006052500000) . CAUTION: Do not damage oil filter. Attach oil filter and tighten bolts evenly.
5. Install the outer gear and inner gear into the sub oil pump housing, and measure the side clearance. Refer to «Sub-oil Pump»(ref-233277-S02394063282006052500000) .
6. Align the dowel pin hole and bolt hole of the sub oil pump assembly with the center case. Install the sub oil pump cover. Then tighten to the specified torque. Refer to «COMPONENTS»(ref-233277-S37893901402006052500000) .
7. Apply ATF to new O-ring and install it to the transfer motor. CAUTION: Do not reuse O-rings.
8. Fit the double-flat end of the transfer motor shaft into the slot of the sub oil pump assembly. Then tighten to the specified torque. Refer to «COMPONENTS»(ref-233277-S37893901402006052500000) . CAUTION: Be sure to install connector bracket.
9. Assemble the control valve assembly with the following procedure. CAUTION: Do not reuse any part that has been dropped or damaged. Make sure valve is assembled in the proper direction. Do not use a magnet because residual magnetism stays during assembly. Clean the upper body, control valves and springs with cleaning agent, and dry with compressed air. Dip the control valves in ATF, and apply ATF to the valve-mounting area of the upper body. Install each control valve, spring, and plug to the upper body, and install retainer plates to hold them in place. CAUTION: To insert control valves into upper body, place upper body on a level surface in order to prevent flaw or damage. Make sure each control valve is smoothly inserted. Install the reverse balls, relief balls and relief springs, accumulator pistons and valve springs to the upper body. Install the lower body and separator plate to the upper body. CAUTION: Do not reuse separator plates. With the lower body down, tighten the two bolts shown. Apply ATF to the O-rings, and install them to each solenoid valve, switch and terminal body. CAUTION: Do not reuse O-rings. Install the following to the control valve assembly: Clutch pressure solenoid valve Clutch pressure switch 2-4WD shift solenoid valve Line pressure switch Transfer fluid temperature sensor
10. Apply ATF to lip seals, and install them to the center case. CAUTION: Do not reuse lip seals. There are 2 kinds of lip seals (lip seal of large inner diameter: 5 pieces, lip seal of small inner diameter: 2 pieces). Confirm their position for installation.
11. Install the control valve assembly to the center case, and tighten to the specified torque. Refer to «COMPONENTS»(ref-233277-S37893901402006052500000) . CAUTION: Do not reuse any part that has been dropped or damaged. Make sure valve is assembled in the proper direction. Do not use a magnet because residual magnetism stays during assembly.
12. Install the connector assembly into the center case, and secure with a snap ring.
13. Apply ATF to new O-rings, and install them on the oil strainer. CAUTION: Do not reuse O-rings.
14. Install the oil strainer to the control valve assembly.
15. Tighten the bolts to the specified torque. Refer to «COMPONENTS»(ref-233277-S37893901402006052500000) .
16. Apply ATF to the D-rings, and install them to the clutch piston. CAUTION: Do not reuse D-rings.
17. Install the thrust needle bearing race to the clutch piston.
18. Install the clutch piston to the center case as shown. CAUTION: Install so the fitting protrusion of clutch piston aligns with the dent of center case.
19. Remove all the sealant from the oil pressure check port and inside the center case. CAUTION: Remove old sealant adhering to mounting surfaces. Also remove any moisture, oil, or foreign material adhering to application and mounting surfaces.
20. Thread the oil pressure check plug in 1 or 2 pitches and apply sealant to the oil pressure check plug threads. Tighten to the specified torque. Refer to «COMPONENTS»(ref-233277-S37893901402006052500000) . Use Genuine Silicone RTV or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-233237-S23907478682006052500000) . CAUTION: Do not reuse oil pressure check plug.
21. Install the snap ring to the clutch hub, using suitable tool. CAUTION: Do not reuse snap ring.
22. Apply petroleum jelly to the needle bearing, and install the needle bearing, spacer, clutch drum and clutch hub to the mainshaft.
23. Install the snap ring to the mainshaft. CAUTION: Do not reuse snap rings.
24. Apply ATF each plate, then install them into the clutch drum as shown.
25. Install the return spring assembly into the clutch hub.
26. Install the press flange by aligning the notches to the clutch hub as shown.
27. Press the press flange to install snap ring into snap ring groove on mainshaft, using Tools. Tool number A: ST22452000 (J-34335) B: ST30911000 ( - ) C: KV31103300 ( - ) CAUTION: Do not reuse snap ring.
28. Install the snap ring to the mainshaft, using suitable tool. CAUTION: Do not reuse snap ring.
29. Apply ATF to the thrust needle bearing and install it on the press flange.
30. Install the snap ring to the main shaft. CAUTION: Do not reuse snap ring.
31. Install the mainshaft rear bearing to the center case, using Tool. Tool number: ST15310000 (J-25640-B)
32. Install the mainshaft assembly, using a press. Press the mainshaft into the center case, using Tools. Tool number A: ST30911000 ( - ) B: ST33052000 ( - )
33. Install the C-rings to the mainshaft.
34. Set the washer holder on the mainshaft, and secure it with a snap ring. CAUTION: Do not reuse snap ring.
35. Apply petroleum jelly to the stem bleeder and install it to the center case.
36. Apply ATF to the seal ring and install it to the main oil pump cover. CAUTION: Do not reuse seal ring.
37. Install the inner gear and outer gear in the main oil pump housing. Then, measure the side clearance. Refer to «Main Oil Pump»(ref-233277-S19543649912006052500000)
38. Install the main oil pump housing, outer gear and inner gear to the center case.
39. Install the main oil pump cover to the center case, and tighten to the specified torque. Refer to «COMPONENTS»(ref-233277-S37893901402006052500000) .
40. Remove all the sealant from the switch mounting area and inside the center case. CAUTION: Remove old sealant adhering to mounting surfaces. Also remove any moisture, oil, or foreign material adhering to application and mounting surfaces.
41. Thread the ATP switch and neutral-4LO switch in one to two pitches and apply sealant to the threads of the switches. Tighten to the specified torque. Refer to «COMPONENTS»(ref-233277-S37893901402006052500000) . Use Genuine Silicone RTV or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-233237-S23907478682006052500000) . NOTE: Neutral-4LO switch harness connector is gray. ATP switch harness connector is black.
42. Install the front drive shaft rear bearing, using Tools. Tool number A: KV40100621 (J-25273) B: ST30032000 (J-26010-01)
43. Install the front drive shaft to the front bearing, using Tools. Tool number A: KV40100621 (J-25273) B: ST30032000 (J-26010-01)
44. Install the drive chain to the front drive shaft and clutch drum. CAUTION: Install drive chain by aligning identification marks to the rear as shown.
45. Tap the front drive shaft while keeping it upright and press-fit the front drive shaft rear bearing. CAUTION: Do not tap drive chain.
46. Install the front case assembly. Refer to «Front Case»(ref-233277-S41274610832006052500000) .
47. Install the rear case assembly. Refer to «Rear Case»(ref-233277-S16452240172006052500000) .

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1. Install the carrier bearing to the sun gear, using Tools. Tool number A: ST30911000 ( - ) B: KV31103300 ( - )
2. Install the snap ring to the sun gear assembly, using suitable tool. CAUTION: Do not reuse snap ring.
3. Apply ATF to the circumference of the metal bushing and install it to the sun gear assembly, using Tool. Dimension A: 7.7 - 8.3 mm (0.303 - 0.327 in) Tool number: ST35300000 ( - ) CAUTION: Do not reuse metal bushing. Apply ATF to metal bushing before installing.
4. Apply ATF to the needle bearing and install it to the sun gear assembly, using Tool. Dimension B: 62.5 - 63.1 mm (2.461 - 2.484 in) Tool number: ST33220000 ( - ) CAUTION: Do not reuse needle bearing. Apply ATF to needle bearing before installing.
5. Install the sun gear assembly to the planetary carrier assembly.
6. Install the snap ring to the planetary carrier assembly. CAUTION: Do not reuse snap ring.
7. Set the mainshaft front bearing into the front case and install, using Tool. Tool number: ST30720000 (J-25405)
8. Install the snap ring into the front case. CAUTION: Do not reuse snap ring.
9. Install the internal gear with its groove facing the snap ring into the front case. Then secure it with the snap ring. CAUTION: Do not reuse snap ring.
10. Install new oil seal until it is seated flush with the end face of the front case, using Tool. Tool number: KV38100500 ( - ) CAUTION: Do not reuse oil seal. Apply petroleum jelly to oil seal lip before installing.
11. Install the planetary carrier assembly and sun gear assembly to the front case, using Tool. Tool number: ST33200000 (J-26082)
12. Install the snap ring to the sun gear assembly. CAUTION: Do not reuse snap ring.
13. Apply petroleum jelly to the circumference of the oil seal, and install it to the front case, using Tools. Dimension: 4.0 - 4.6 mm (0.157 - 0.181 mm) Tool number A: ST30720000 (J-25405) B: ST33200000 (J-26082) CAUTION: Do not reuse oil seal. Apply petroleum jelly to oil seal.
14. Install the fork guide, shift fork spring, 2-4 fork, and L-H fork to the shift rod, and secure them with retaining pins. CAUTION: Do not reuse retaining pins.
15. Install the 2-4 sleeve and L-H sleeve to each fork.
16. Install the shift cross to the front case.
17. While aligning the L-H sleeve with the planetary carrier, install the shift rod assembly to the front case.
18. Apply liquid gasket to the entire center case mounting surface of the front case assembly as shown. Use Genuine Anaerobic Liquid Gasket or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-233237-S23907478682006052500000) . CAUTION: Remove all foreign materials such as water, oil and grease from center case and front case mating surfaces.
19. Install the center case assembly to the front case assembly. CAUTION: Do not damage mainshaft end.
20. Tap the center case lightly and press-fit the front drive shaft bearing into the front case.
21. Tighten the front case bolts to the specified torque. Refer to «COMPONENTS»(ref-233277-S37893901402006052500000) . CAUTION: Be sure to install air breather hose clamp, connector bracket and harness clip.
22. Install the drain plug with a new gasket. CAUTION: Do not reuse gasket.
23. Align the matching mark on the front drive shaft with the mark on the companion flange, then install the companion flange.
24. Install the companion flange self-lock nut. Tighten to the specified torque, using Tool. Refer to «COMPONENTS»(ref-233277-S37893901402006052500000) . Tool number: KV40104000 ( - ) CAUTION: Do not reuse self-lock nut.
25. Remove all the sealant from the check plug, switch mounting and front case. CAUTION: Remove old sealant adhering to mounting surfaces. Also remove any moisture, oil, or foreign material adhering to application and mounting surfaces.
26. Install the check ball and check spring to the front case. Apply silicone gasket, to the check plug and wait detection switch and install them to the front case. Tighten to the specified torque. Refer to «COMPONENTS»(ref-233277-S37893901402006052500000) . Use Genuine Silicone RTV or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-233237-S23907478682006052500000) . NOTE: Wait detection switch harness connector is black.
27. Install the oil seal in the front case, using Tool. Tool number: ST22360002 (J-25679-01) CAUTION: Do not reuse oil seal. Apply petroleum jelly to seal lip before installing.
28. Install the shift lever to the shift cross.
29. Install the lock pin and lock pin nut. Tighten to the specified torque. Refer to «COMPONENTS»(ref-233277-S37893901402006052500000) .

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1. Apply petroleum jelly to the circumference of the rear oil seal. Install the rear oil seal so that it is flush with the case tip face, using Tool. Tool number: ST30720000 (J-25405) CAUTION: Do not reuse oil seal. Apply petroleum jelly to seal lip before installing.
2. Apply petroleum jelly to the circumference of the dust cover. Position the dust cover using the identification mark as shown. CAUTION: Do not reuse dust cover. Position the identification mark at the position shown.
3. Install the dust cover, using Tool. Tool number: KV40105310 ( - )
4. Install the air breather into the rear case.
5. Remove all the sealant from the rear case to center case mounting surfaces. CAUTION: Remove all foreign materials such as water, oil, and grease from center case and rear case mating surfaces.
6. Apply liquid gasket to the entire rear case mounting surface of the center case. Use Genuine Anaerobic Liquid Gasket or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-233237-S23907478682006052500000) . CAUTION: Do not to allow Liquid Gasket to enter stem bleeder hole.
7. Install the rear case to the center case. Tighten the bolts to the specified torque. Refer to «COMPONENTS»(ref-233277-S37893901402006052500000) .