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Front Case

  1. Install the carrier bearing to the sun gear using Tools.

    Tool number A: ST30911000 ( - ) 

    B: KV31103300 ( - ) 

    Fig 1: Installing Carrier Bearing To Sun Gear
    G04901750
  2. Install the new snap ring to the sun gear assembly using suitable tool.
    CAUTION: Do not reuse snap ring.
    Fig 2: Installing Snap Ring
    G04901644
  3. Apply ATF to the circumference of the new metal bushing and install it to the sun gear assembly using Tool.

    Tool number : ST35300000 ( - ) 

    Dimension A : 7.7 - 8.3 mm (0.303 - 0.327 in) 

    Fig 3: Installing Sun Gear Assembly
    G04901752
    CAUTION:
    • Do not reuse metal bushing.
    • Apply ATF to metal bushing before installing.
  4. Apply ATF to the new needle bearing and install it to the sun gear assembly using Tool.

    Tool number : ST33220000 ( - ) 

    Dimension B : 62.5 - 63.1 mm (2.461 - 2.484 in) 

    Fig 4: Installing Sun Gear Assembly
    G04901753
    CAUTION:
    • Do not reuse needle bearing.
    • Apply ATF to needle bearing before installing.
  5. Install the sun gear assembly to the planetary carrier assembly.
    Fig 5: Installing Sun Gear Assembly To Planetary Carrier Assembly
    G04901754
  6. Install the new snap ring to the planetary carrier assembly.
    CAUTION: Do not reuse snap ring.
    Fig 6: Installing Snap Ring
    G04901755
  7. Set the input bearing into the front case and install using Tool.

    Tool number : ST30720000 (J-25405) 

    Fig 7: Setting Input Bearing Into Front Case
    G04901756
  8. Install the new snap ring into the front case.
    CAUTION: Do not reuse snap ring.
    Fig 8: Identifying Snap Ring
    G04901640
  9. Install the internal gear with its groove facing the new snap ring into the front case. Then secure it with the new snap ring.
    CAUTION: Do not reuse snap ring.
    Fig 9: Identifying Internal Gear And Snap Ring
    G04901758
  10. Install new front 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 front oil seal lip before installing.
      Fig 10: Installing Front Oil Seal
      G04901759
  11. Install the planetary carrier assembly and sun gear assembly to the front case using Tool.

    Tool number : ST33200000 (J-26082) 

    Fig 11: Installing Planetary Carrier Assembly And Sun Gear Assembly
    G04901760
  12. Install the new snap ring to the sun gear assembly.
    CAUTION: Do not reuse snap ring.
    Fig 12: Identifying Snap Ring
    G04901636
  13. Apply petroleum jelly to the circumference of the new input oil seal, and install it to the front case using Tools.

    Tool number A: ST30720000 (J-25405) 

    B: ST33200000 (J-26082) 

    Dimension "A" : 4.0 - 4.6 mm (0.157 - 0.181 mm) 

    CAUTION:
    • Do not reuse input oil seal.
    • Apply petroleum jelly to input oil seal.
      Fig 13: Installing Input Oil Seal
      G04901762
  14. Install the fork guide, shift fork spring, 2-4 fork, and L-H fork to the shift rod, and secure them with new retaining pins.
    CAUTION: Do not reuse retaining pins.
    Fig 14: Identifying Fork Guide, Shift Fork Spring, 2-4 Fork, And L-H Fork
    G04901634
  15. Install the 2-4 sleeve and L-H sleeve to each fork.
  16. Install the shift cross to the front case.
    Fig 15: Identifying 2-4 Sleeve And L-H Sleeve
    G04901632
  17. While aligning the L-H sleeve with the planetary carrier, install the shift rod assembly to the front case.
    Fig 16: Installing Shift Rod Assembly
    G04901631
  18. Apply liquid gasket to the entire center case mating surface of the front case assembly as shown.
    • Use Genuine Anaerobic Liquid Gasket or equivalent.  Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".
      CAUTION: Remove all foreign materials such as water, oil and grease from center case and front case mating surfaces.
      Fig 17: Identifying Liquid Gasket Applying Area
      G04901766
  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.
    Fig 18: Installing Center Case Assembly To Front Case Assembly
    G04901767
  21. Tighten the front case bolts to the specified torque. Refer to "COMPONENTS ".
    CAUTION: Be sure to install harness bracket and air breather hose clamp.
  22. Install the drain plug with a new gasket.
    CAUTION: Do not reuse gasket.
    Fig 19: Locating Front Case Bolts
    G04901629
  23. Align the matching mark on the front drive shaft with the mark on the companion flange, then install the companion flange.
    Fig 20: Aligning Front Drive Shaft Matching Mark With Companion Flange Mark
    G04901627
  24. Install the new companion flange self-lock nut. Tighten to the specified torque using Tool. Refer to "COMPONENTS ".

    Tool number : KV40104000 ( - ) 

    CAUTION: Do not reuse self-lock nut.
    Fig 21: Installing Companion Flange Self-Lock Nut
    G04901770
  25. Remove all the sealant from the check plug, switch mating surface and front case.
    CAUTION: Remove old sealant adhering to mating surfaces. Also remove any moisture, oil, or foreign material adhering to application and mating 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 ".
  27. Install the new 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 ".
    Fig 23: Installing Oil Seal Into Front Case
    G04901772
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