TRANSFER GI

SECTION TF MA

EM

LC

EC

CONTENTS FE

PREPARATION ...............................................................2 ASSEMBLY .............................................................23

CL
Special Service Tools ..................................................2 Main Gear ..................................................................23
Commercial Service Tools ...........................................3 DISASSEMBLY ........................................................23 MT
NOISE, VIBRATION AND HARSHNESS (NVH) INSPECTION ...........................................................24
TROUBLESHOOTING .....................................................5 ASSEMBLY .............................................................24
NVH Troubleshooting Chart.........................................5 Front Case .................................................................25 AT
TRANSFER ...............................................................5 REMOVAL ...............................................................25
INSTALLATION........................................................25
DESCRIPTION .................................................................6
Front Case Cover ......................................................25
Cross-sectional View ...................................................6
REMOVAL ...............................................................25
ON-VEHICLE SERVICE ..................................................7
INSTALLATION........................................................25
Replacing Oil Seal .......................................................7
Bearing Retainer........................................................26 PD
CENTER CASE OIL SEAL ..........................................7
REMOVAL ...............................................................26
SHIFT SHAFT OIL SEAL ............................................8
INSTALLATION........................................................26
REAR OIL SEAL ........................................................8 AX
Center Case...............................................................26
Position Switch Check .................................................9
REMOVAL ...............................................................26
REMOVAL AND INSTALLATION .................................10
INSTALLATION........................................................26
Removal.....................................................................10 Rear Case..................................................................26 SU
Installation..................................................................10 REMOVAL ...............................................................26
M/T MODEL ............................................................10 INSTALLATION........................................................27
A/T MODEL .............................................................10 Shift Control Components .........................................27
BR
OVERHAUL ...................................................................11 INSPECTION ...........................................................27
Transfer Gear Control................................................11 ASSEMBLY....................................................................29
Case Components .....................................................12
ST
SERVICE DATA AND SPECIFICATIONS (SDS) .........37
Gear Components .....................................................13 General Specifications...............................................37
Shift Control Components .........................................14 Inspection and Adjustment ........................................37 RS
DISASSEMBLY..............................................................15 CLEARANCE BETWEEN FRONT DRIVE
REPAIR FOR COMPONENT PARTS ...........................20 SPROCKET AND 2-4 COUPLING SLEEVE................37
Mainshaft ...................................................................20 GEAR END PLAY ....................................................37 BT
DISASSEMBLY ........................................................20 CLEARANCE BETWEEN BAULK RING AND
INSPECTION ...........................................................21 CLUTCH GEAR .......................................................37
ASSEMBLY .............................................................22 Available Shim ...........................................................37 HA
Front Drive Shaft .......................................................22 COUNTER GEAR REAR BEARING ...........................37
DISASSEMBLY ........................................................22 Available Snap Ring ..................................................38
INSPECTION ...........................................................22 MAINSHAFT FRONT BEARING ................................38 SC
ASSEMBLY .............................................................22 MAIN GEAR BEARING.............................................38
Counter Gear .............................................................23 MAINSHAFT REAR BEARING ..................................38
DISASSEMBLY ........................................................23
EL
INSPECTION ...........................................................23

IDX
 PREPARATION
Special Service Tools

Special Service Tools NGTF0001

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.

Tool number
(Kent-Moore No.) Description
Tool name

KV38108300 Removing companion flange nut

(—) Installing companion flange nut
Companion Flange
wrench

NT771

ST30021000 Removing counter gear front bearing

(J22912-01) (Use with ST36710010)
Puller Removing L & H hub
a: 110 mm (4.33 in) dia.
b: 68 mm (2.68 in) dia.

NT411

ST30031000 Removing counter gear rear bearing

(J22912-01) (Use with ST36710010)
Puller a: 90 mm (3.54 in) dia.
b: 50 mm (1.97 in) dia.

NT411

ST33290001 Removing center case oil seal

(J34286) Removing rear oil seal
Puller a: 250 mm (9.84 in)
b: 160 mm (6.30 in)

NT414

ST33051001 Removing companion flange

(J22888) a: 135 mm (5.31 in)
Puller b: 100 mm (3.94 in)
c: 130 mm (5.12 in)

NT657

ST30720000 1 Installing center case oil seal

1 (J25273) 2 Installing rear oil seal
2 (J25405) a: 77 mm (3.03 in) dia.
Drift b: 55.5 mm (2.185 in) dia.

NT658

TF-2
 PREPARATION
Special Service Tools (Cont’d)

Tool number
(Kent-Moore No.) Description
Tool name GI
ST36710010 Removing counter gear front bearing
( — ) (Use with ST30021000) MA
Drift Removing counter gear rear bearing
(Use with ST30031000)
a: 34.5 mm (1.358 in) dia.
NT063
EM
ST33061000 Removing main gear bearing
(J8107-2) a: 28.5 mm (1.122 in) dia. LC
Drift b: 38 mm (1.50 in) dia.

EC
NT116

ST30613000 1 Installing main gear bearing

1 (J25742-3) 2 Installing front case cover oil seal FE
2 (J34339) a: 72 mm (2.83 in) dia.
Drift b: 48 mm (1.89 in) dia.
CL
NT073

(J35864) Installing shift shaft oil seal MT

Drift a: 26 mm (1.02 in) dia.
b: 20 mm (0.79 in) dia.
c: 150 mm (5.91 in) AT
NT117

(J26092) Seating counter gear assembly

Drift a: 44.5 mm (1.752 in) dia.
b: 38.5 mm (1.516 in) dia.
PD
NT065

(J34291) Selecting counter gear rear bearing shim

AX
Shim setting gauge set

SU

NT101
BR
(J34291-20) Selecting counter gear rear bearing shim
Plunger-shim setting ST
gauge

RS
NT118

Commercial Service Tools NGTF0002

BT
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.

Tool name Description HA

Puller Removing front drive shaft front bearing
Removing front drive shaft rear bearing
Removing main gear bearing SC

EL
NT077

IDX
TF-3
 PREPARATION
Commercial Service Tools (Cont’d)

Tool name Description

Drift 1 Installing mainshaft rear bearing

2 Installing L & H hub
1 a: 50 mm (1.97 in) dia.
b: 42 mm (1.65 in) dia.
c: 180 mm (7.09 in)
2 a: 60 mm (2.36 in) dia.
NT117
b: 50 mm (1.97 in) dia.
c: 60 mm (2.36 in)

TF-4
 NGTF0039

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NVH Troubleshooting Chart

NVH Troubleshooting Chart NGTF0039S01

Use the chart below to help you find the cause of the symptom. The numbers indicate the order of inspection.
If necessary, repair or replace these parts. GI
TRANSFER NGTF0039S0101
MA

MA-36, ″Checking Transfer Fluid″.

EM

TF-12, TF-14
TF-12

TF-12

TF-14

TF-13

TF-13

TF-13

TF-13
Reference page LC

EC

FE

CHECK SPRING AND CHECK BALL (Worn damaged)

CL

BAULK RING (Worn or damaged)

SHIFTING INSERT (Damaged)

OIL SEAL (Worn or damaged)
LIQUID GASKET (Damaged)

Bearing (Worn or damaged)

GEAR (Worn or damaged)
FLUID (Level too high) MT

SHIFT FORK (Worn)

FLUID (Level low)

FLUID (Wrong)

SUSPECTED PARTS
AT
(Possible cause)

PD

AX

Noise 1 2 3 3
SU
Fluid leakage 3 1 2 2
Symptom
Hard to shift or will not shift 1 1 2 2 BR
Jumps out of gear 1 2 2

ST

RS

BT

HA

SC

EL

IDX
TF-5
 DESCRIPTION
Cross-sectional View

Cross-sectional View NGTF0003

ATF021

TF-6
 ON-VEHICLE SERVICE
Replacing Oil Seal

Replacing Oil Seal NGTF0004

CENTER CASE OIL SEAL
1.
NGTF0004S01
Remove front propeller shaft. Refer to PD-7, “Removal and
GI
Installation”.
2. Remove companion flange nut. MA

EM

SMT844D LC
3. Remove companion flange.
EC

FE

CL

SMT486A
MT
4. Remove center case oil seal.
5. Install center case oil seal. AT
쐌 Before installing, apply multi-purpose grease to seal lip.
6. Install companion flange.

PD

AX
AMT086

7. Tighten companion flange nut.

: 226 - 324 N·m (23 - 33 kg-m, 166 - 239 ft-lb)
SU
8. Install front propeller shaft. Refer to PD-7, “Removal and
Installation”. BR

ST

RS
SMT845D

BT

HA

SC

EL

IDX
TF-7
 ON-VEHICLE SERVICE
Replacing Oil Seal (Cont’d)
SHIFT SHAFT OIL SEAL NGTF0004S02
1. Remove front propeller shaft. Refer to PD-7, “Removal and
Installation”.
2. Remove companion flange. Refer to “CENTER CASE OIL
SEAL”, TF-7.
3. Remove transfer control lever from transfer outer shift lever.
Then remove outer shift lever.

ATF007

4. Remove shift shaft oil seal.

쐌 Be careful not to damage cross shaft.

SMT491A

5. Install shift shaft oil seal.

쐌 Before installing, apply multi-purpose grease to seal lip.
6. Install transfer control linkage.
7. Install companion flange. Refer to “CENTER CASE OIL
SEAL”, TF-7.
8. Install front propeller shaft. Refer to PD-7, “Removal and
Installation”.

SMT492A

REAR OIL SEAL NGTF0004S03

1. Remove rear propeller shaft. Refer to PD-7, “Removal and
Installation”.
2. Remove rear oil seal.

AMT087

3. Install rear oil seal.

쐌 Before installing apply multi-purpose grease to seal lip.
4. Install rear propeller shaft. Refer to PD-7, “Removal and
Installation”.

SMT494A

TF-8
 ON-VEHICLE SERVICE
Position Switch Check

Position Switch Check NGTF0042

Switch Gear Position Continuity GI

4WD Yes
4WD Switch
Except 4WD NO MA
Neutral NO
Neutral Position Switch
Except Neutral Yes EM

SMT790CA LC

EC

FE

CL

MT

AT

PD

AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX
TF-9
 REMOVAL AND INSTALLATION
Removal

Removal NGTF0006
1. Drain fluid from transfer, and drain oil from transmission.
2. Remove front and rear propeller shaft. Refer to PD-7,
“Removal and Installation”.
Insert plug into rear oil seal after removing propeller shaft.
쐌 Be careful not to damage spline, sleeve yoke and rear oil
seal, when removing propeller shaft.
3. Remove torsion bar spring. Refer to SU-13, “Torsion Bar
Spring”. Then remove second crossmember.
4. Remove exhaust front and rear tubes. Refer to FE-9,
ATF020 “EXHAUST SYSTEM”.
5. Disconnect vehicle speed sensor, transfer neutral position
switch and 4WD switch harness connectors.
6. Remove air breather hose.
7. Remove transfer control lever from transfer outer shift lever.
8. Separate transfer from transmission.
WARNING:
Support transfer while removing it.

ATF007

Installation NGTF0007
쐌 Apply sealant to mating surface to transmission. (M/T model
only)
Use genuine anaerobic liquid gasket, Three Bond
TB1215, Loctite Part No. 51813 or equivalent.

SMT495A

쐌 Tighten bolts securing transfer.

M/T MODEL NGTF0007S01

Tightening torque
Bolt No.
mm (in)
N·m (kg-m, ft-lb)

1 31 - 41 (3.2 - 4.2, 23 - 30) 45 (1.77)

2 31 - 41 (3.2 - 4.2, 23 - 30) 60 (2.36)

A/T MODEL NGTF0007S02

ATF026
Tightening torque
Bolt No.
mm (in)
N·m (kg-m, ft-lb)

1 31 - 41 (3.2 - 4.2, 23 - 30) 45 (1.77)

2 31 - 41 (3.2 - 4.2, 23 - 30) 45 (1.77)

TF-10
 OVERHAUL
Transfer Gear Control

Transfer Gear Control NGTF0008

GI

MA

EM

LC

EC

FE

CL

MT

AT

PD

AX

SU

BR

ST

RS

BT

HA

SC

ATF027 EL

IDX
TF-11
 OVERHAUL
Case Components

Case Components NGTF0009

WTF001

TF-12
 OVERHAUL
Gear Components

Gear Components NGTF0010

GI

MA

EM

LC

EC

FE

CL

MT

AT

PD

AX

SU

BR

ST

RS

BT

HA

SC

WTF002 EL

IDX
TF-13
 OVERHAUL
Shift Control Components

Shift Control Components NGTF0011

ATF025

TF-14
 NGTF0012

DISASSEMBLY

1. Remove companion flange nut.

2. Remove companion flange.
GI

MA

EM

WTF003 LC
3. Remove 4WD switch.
4. Remove rear case.
EC
쐌 Be careful not to damage the mating surface.

FE

CL

SMT270A
MT
5. Remove oil cover and oil gutter.
6. Remove snap ring and retainer ring from 2-4 shift rod. AT

PD

AX
SMT435C

7. Using calipers, measure the difference between front drive

sprocket and 2–4 coupling sleeve as outlined under measur- SU
ing method below. If it is outside specifications, check front
drive sprocket, 2–4 coupling sleeve, clutch gear, 2–4 shift fork
and 2–4 fork rod for abnormalities. Replace faulty part(s) as BR
required.
Measuring method
ST
Move Coupling sleeve until it is in contact with
sprocket, then measure dimension A. Move coupling
sleeve until it is in contact with clutch gear, then mea- RS
sure dimension B. Obtain dimension difference C
between two measurements A and B.
A–B=C BT
To determine dimension A, measure at 3 or 4 different
points by rotating sprocket and obtain average value of
3 or 4 measurements. HA
Specification C: Refer to “Clearance Between Front
Drive Sprocket and 2–4 Coupling Sleeve”, TF-37.
SC

EL
SMT799CA
IDX
TF-15
 DISASSEMBLY

8. Remove bolts securing bearing retainer.

쐌 This step is necessary to remove mainshaft from center
case.

SMT273A

9. Remove bolts securing center case to front case and then

separate center case and front case.

SMT274A

10. Measure low gear end play.

Standard:
0.2 - 0.35 mm (0.0079 - 0.0138 in)
쐌 If end play is beyond the maximum value, check low gear
and L & H hub for wear.

SMT342A

11. Disassemble center case assembly.

a. Remove snap ring from mainshaft.

SMT275A

b. Pull out low gear with L & H hub.

SMT757A

TF-16
 DISASSEMBLY

c. Remove needle bearing from main shaft.

GI

MA

EM

SMT758A LC
d. Make sure of the direction of the drive chain before removing
it. (It must be reinstalled in the same direction.)
EC

FE

CL

SMT788C
MT
e. Remove mainshaft, front drive and drive chain as a set by
tapping front end of mainshaft and front drive shaft alternately. AT
쐌 Be careful not to bend drive chain.

PD

AX
SMT279A

12. Disassemble front case assembly.

a. Remove transfer neutral position switch, plugs, check springs
SU
and check balls.
BR

ST

RS
ATF019

b. Remove lock pin from outer shift lever, then remove outer shift BT
lever.

HA

SC

EL
ATF013
IDX
TF-17
 DISASSEMBLY

c. Remove lock pin of inner shift lever and drive out cross shaft
with plug.

SMT282A

d. Remove 2-4 shift rod.

SMT283A

e. Remove L & H shift rod and fork assembly with coupling

sleeve.

SMT284A

f. Remove needle bearing from main gear.

SMT286A

g. Remove bolts securing front case cover and then remove

case.

SMT287A

TF-18
 DISASSEMBLY

h. Remove counter gear by tapping lightly.

GI

MA

EM

SMT759A LC
i. Remove main gear by tapping lightly.
EC

FE

CL

SMT288A
MT

AT

PD

AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX
TF-19
 REPAIR FOR COMPONENT PARTS
Mainshaft

Mainshaft
DISASSEMBLY NGTF0013
1. Check front drive sprocket end play.
Standard:
0.2 - 0.35 mm (0.0079 - 0.0138 in)
쐌 If end play is not within specification, check front drive
sprocket and clutch gear for wear.

SMT347A

2. Remove retainer ring, speedometer drive gear and steel ball.

쐌 Be careful not to lose the steel ball.

SMT289A

3. Remove snap ring and spacer.

SMT290A

4. Use a press to remove front drive sprocket with mainshaft rear

bearing and clutch gear together.
5. Remove needle bearing.

SMT291A

6. Remove bearing retainer and then remove snap ring.

SMT292A

TF-20
REPAIR FOR COMPONENT PARTS
Mainshaft (Cont’d)
7. Use a press to remove mainshaft front bearing from mainshaft.

GI

MA

EM

SMT293A LC
INSPECTION NGTF0014
Gear and Shaft NGTF0014S01 EC
쐌 Check gears for excessive wear, chips or cracks.
쐌 Check shaft for cracks, wear or bending.
쐌 Check coupling sleeve for wear or damage. FE

CL

SMT348A
MT
Baulk ring NGTF0014S03
쐌 Check baulk ring for cracks or deformation. AT

PD

AX
SMT349A

쐌 Measure clearance between baulk ring and clutch gear.

Baulk ring to clutch gear clearance:
SU
Refer to “CLEARANCE BETWEEN BAULK RING AND
CLUTCH GEAR”, TF-37. BR

ST

RS
SMT350A

Bearing NGTF0014S02
BT
쐌 Make sure bearings roll freely and are free from noise, cracks,
pitting or wear.
HA

SC

EL
SMT351A
IDX
TF-21
 REPAIR FOR COMPONENT PARTS
Mainshaft (Cont’d)
ASSEMBLY NGTF0015
1. Press mainshaft front bearing onto mainshaft.
쐌 Pay special attention to its direction.

SMT294A

2. Select snap ring with proper thickness.

Allowable clearance between snap ring and groove:
0 - 0.15 mm (0 - 0.0059 in)
Available snap ring for mainshaft front bearing:
Refer to “MAINSHAFT FRONT BEARING”, TF-38.
3. Regarding to further procedures, refer to “ASSEMBLY”, TF-29.

SMT295A

Front Drive Shaft

DISASSEMBLY NGTF0016
쐌 Using a gear puller, remove front drive shaft front and rear
bearings

SMT437C

INSPECTION NGTF0017
Sprocket and Shaft NGTF0017S01
쐌 Check sprocket for excessive wear, chips or cracks.
쐌 Check shaft for cracks or wear.
Bearing NGTF0017S02
쐌 Make sure bearings roll freely and are free from noise, cracks,
pitting or wear.

SMT357A

ASSEMBLY NGTF0018
쐌 Press front drive shaft front and rear bearings onto front drive
shaft.

SMT438C

TF-22
REPAIR FOR COMPONENT PARTS
Counter Gear

Counter Gear
DISASSEMBLY
1. Press out counter gear front bearing.
NGTF0019
GI
쐌 Remove front sub-gear, dish plate and spacer (M/T model
only). MA

EM

AMT093 LC
2. Press out counter gear rear bearing.
쐌 Remove rear sub-gear, dish plate and spacer (M/T model
only).
EC

FE

CL

SMT301A
MT
INSPECTION NGTF0020
Gear and Shaft NGTF0020S01
AT
쐌 Check gears for excessive wear, chips or cracks.
쐌 Check shaft for cracks or wear.
Bearing NGTF0020S02
쐌 Make sure bearings roll freely and are free from noise, cracks,
pitting or wear. PD

AX
SMT358A

ASSEMBLY
1.
NGTF0021
Install front sub-gear, dish plate and spacer (M/T model only).
SU
2. Press on counter gear front bearing.
3. Install rear sub-gear, dish plate and spacer (M/T model only). BR
4. Press on counter gear rear bearing.
ST

RS
SMT439C

Main Gear BT
DISASSEMBLY NGTF0022
Main Gear Bearing NGTF0022S01 HA
1. Remove snap ring.

SC

EL
SMT304A
IDX
TF-23
 REPAIR FOR COMPONENT PARTS
Main Gear (Cont’d)
2. Pull out main gear bearing.

SMT305A

Plug NGTF0022S02
쐌 Always replace it with new one whenever it has been
removed.

SMT306A

INSPECTION NGTF0023
Gear and Shaft NGTF0023S01
쐌 Check gears for excessive wear, chips or cracks.
쐌 Check shaft for cracks or wear.
Bearing NGTF0023S02
쐌 Make sure bearings roll freely and are free from noise, cracks,
pitting or wear.

SMT359A

ASSEMBLY NGTF0024
Main Gear Bearing NGTF0024S01
1. Press on main gear bearing.

SMT307A

2. Select and install snap ring with proper thickness.

Allowable clearance between snap ring and groove:
0 - 0.15 mm (0 - 0.0059 in)
Available snap ring for main gear bearing:
Refer to “MAIN GEAR BEARING”, TF-38.

ATF014

TF-24
REPAIR FOR COMPONENT PARTS
Main Gear (Cont’d)
Plug NGTF0024S02
Apply sealant to plug, then install.
쐌 Use genuine anaerobic liquid gasket, Three Bond TB1215, GI
Loctite part No. 51813 or equivalent.
MA

EM

SMT309A LC
Front Case
REMOVAL NGTF0025
EC
Shift Shaft Oil Seal NGTF0025S01
쐌 Use a screwdriver to pry out old seal.
쐌 Be careful not to damage case.
FE
쐌 Always replace with a new one whenever it has been removed.
CL

SMT310A
MT
INSTALLATION NGTF0026
Shift Shaft Oil Seal NGTF0026S01
AT
쐌 Install new shift shaft oil seal until flush with case.
쐌 Before installing, apply multi-purpose grease to seal lip.

PD

AX
SMT311A

Front Case Cover SU

REMOVAL NGTF0027
Cover Oil Seal
쐌 Drive out old seal from inside of front case cover.
NGTF0027S01
BR
쐌 Be careful not to damage front case cover.
ST

RS
SMT312A

INSTALLATION NGTF0028
BT
Cover Oil Seal NGTF0028S01
쐌 Install new front case cover oil seal until it stops.
쐌 Before installing, apply multi-purpose grease to seal lip.
HA

SC

EL
SMT313A
IDX
TF-25
 REPAIR FOR COMPONENT PARTS
Bearing Retainer

Bearing Retainer
REMOVAL NGTF0029
Oil Catcher NGTF0029S01
쐌 Drive out oil catcher from inside of bearing retainer.
쐌 Be careful not to damage bearing retainer.

SMT314A

INSTALLATION NGTF0030
Oil Catcher NGTF0030S01
쐌 Install oil catcher until it stops.
쐌 Be careful not to damage or distort oil catcher or bearing
retainer.
쐌 Before installing, apply multi-purpose grease to seal lip.

SMT315A

Center Case
REMOVAL NGTF0044
Center Case Oil Seal NGTF0044S01
쐌 Remove center case oil seal.

SMT863D

INSTALLATION NGTF0045
Center Case Oil Seal NGTF0045S01
쐌 Install center case oil seal.

SMT864D

Rear Case
REMOVAL NGTF0031
Rear Oil Seal NGTF0031S01
쐌 Pull out rear oil seal.

AMT094

TF-26
REPAIR FOR COMPONENT PARTS
Rear Case (Cont’d)
INSTALLATION NGTF0032
Rear Oil Seal
쐌 Install new rear oil seal until it stops.
NGTF0032S01
GI
쐌 Before installing, apply multi-purpose grease to seal lip.
MA

EM

SMT317A LC
Air Breather NGTF0032S02
Install as shown in illustration. EC
쐌 Use genuine thread locker, Three Bond TB1324, Loctite
271 or equivalent.
FE

CL

SMT799A
MT
Shift Control Components
INSPECTION AT
NGTF0033
쐌 Check contact surface and sliding surface for wear, scratches,
projections or other faulty conditions.

PD

AX
SMT360A

L & H Shift Rod & Fork

쐌 Assemble as shown in illustration.
NGTF0033S01 SU
* Retaining pin is the same size as the one for 2-4 shift rod.
BR

ST

RS
SMT319A

2-4 Shift Rod & Fork NGTF0033S02

BT
쐌 Assemble as shown in illustration.
* Retaining pins are the same size.
HA

SC

EL
SMT320A
IDX
TF-27
 REPAIR FOR COMPONENT PARTS
Shift Control Components (Cont’d)
쐌 Pay special attention to the direction of fork guide collar.

SMT321A

TF-28
 NGTF0034

ASSEMBLY

1. Assemble front case.

a. Install main gear assembly by tapping lightly.
GI

MA

EM

SMT323A LC
b. Apply sealant to the mating surface and bolts of front case
cover, then attach it to the front case.
쐌 Use genuine anaerobic liquid gasket, Three Bond TB1215,
EC
Loctite Part No. 51813 or equivalent.
쐌 These ten bolts should be coated with sealant. FE
Bolts A: 16 - 21 N·m (1.6 - 2.1 kg-m, 12 - 15 ft-lb)
Bolts B: 19 - 24 N·m (1.9 - 2.4 kg-m, 14 - 17 ft-lb)
CL

SMT325A
MT
c. Apply ATF to needle bearing and install it into main gear.
AT

PD

AX
SMT326A

d. Install counter gear assembly by tapping lightly.

SU

BR

ST

RS
SMT327A

e. Install cross shaft and inner shift lever. BT

쐌 When replacing cross shaft, outer shift lever or outer shift
lever lock pin, replace them as a set.
HA

SC

EL
SMT798A
IDX
TF-29
 ASSEMBLY

f. Apply sealant to plug and install it into front case.

Use genuine anaerobic liquid gasket, Three Bond TB1215,
Loctite Part No. 51813 or equivalent.

SMT330A

g. Insert interlock plunger into front case.

SMT331A

h. Install L & H shift rod and fork assembly with coupling sleeve.

SMT332A

i. Install 2-4 shift rod.

ATF015

j. Install transfer neutral position switch, check balls, check

springs and plugs.
쐌 Apply sealant to switches and plugs.
쐌 Use genuine anaerobic liquid gasket, Three Bond TB1215,
Loctite Part No. 51813 or equivalent.

ATF019

TF-30
 ASSEMBLY

2. Select counter gear rear bearing shim.

a. Seat counter gear assembly.
GI

MA

EM

SMT590A LC
b. Place J34291-1 (bridge), J34291-2 (legs) and J34291-5 (gaug-
ing cylinder) on machined surface of center case, allowing
gauging cylinder to rest on top outer portion of counter gear EC
rear bearing. Lock gauging cylinder in place.
FE

CL

SMT591A
MT
c. Insert J34291-20 (gauging plunger) into J34291-5 (gauging
cylinder). AT

PD

AX
SMT592A

d. Place bridge, legs, gauging cylinder and gauging plunger onto

machined surface of front case assembly, allowing gauging SU
plunger to drop until it contacts counter gear rear bearing mat-
ing surface.
BR

ST

RS

BT

HA

SC

EL
SMT593A
IDX
TF-31
 ASSEMBLY

e. Lock gauging plunger in place and use feeler gauge to mea-

sure end play between gauging cylinder and gauging plunger.
f. Use measured distance to select correct counter gear rear
bearing shim.
Allowable counter gear end play:
0 - 0.2 mm (0 - 0.008 in)
Allowable counter gear rear bearing shim:
Refer to “COUNTER GEAR REAR BEARING”, TF-37.

SMT594A

3. Place suitable shim with grease on counter gear rear bearing.

4. Apply ATF to each part in front case.

SMT336A

5. Assemble center case assembly.

a. Install mainshaft on center case by tapping lightly.
쐌 Apply ATF to mainshaft front bearing.

SMT406A

b. Install bearing retainer.

: 16 - 21 N·m (1.6 - 21 kg-m, 12 - 15 ft-lb)

SMT407A

TF-32
 ASSEMBLY

c. Put drive chain onto the front drive sprocket and front drive
shaft, and then put them in center case.
GI

MA

EM

SMT408A LC

EC

FE

CL

SMT409A
MT
d. Install front drive shaft by tapping lightly.
쐌 Make sure shafts are aligned in the case. AT

PD

AX
SMT410A

e. Apply ATF to needle bearings and install them into front drive
sprocket. SU
쐌 These needle bearings can be installed more easily if front
drive sprocket is rotated while installing them.
BR

ST

RS
SMT411A

f. Install 2-4 coupling sleeve with 2-4 shift fork. BT

쐌 Pay special attention to direction of coupling sleeve.

HA

SC

EL
SMT412A
IDX
TF-33
 ASSEMBLY

g. Install shifting inserts and spread spring.

쐌 Pay attention to the direction of shifting inserts.

SMT353A

h. Install baulk ring, then install clutch gear and mainshaft rear
bearing.
쐌 Place wooden block under mainshaft in order to protect
mainshaft front bearing.

SMT413A

i. Install spacer.
j. Select and install snap ring with proper thickness.
Allowable clearance between snap ring and groove:
0 - 0.15 mm (0 - 0.0059 in)
Available snap ring for mainshaft rear bearing:
Refer to “MAINSHAFT REAR BEARING”, TF-38.

SMT414A

k. Install steel ball, speedometer drive gear and retainer ring.

쐌 Steel ball is the smallest of check balls for this unit.

SMT415A

l. Install low gear and its bearing onto mainshaft.

쐌 Apply ATF to needle bearing.

SMT340A

TF-34
 ASSEMBLY

m. Install L & H hub and snap ring to mainshaft.

쐌 Pay attention to direction of L & H hub.
GI

MA

EM

SMT760A LC
n. Measure low gear end play.
Standard:
EC
0.2 - 0.35 mm (0.0079 - 0.0138 in)

FE

CL

SMT342A
MT
6. Apply sealant to mating surface of center case then attach to
front case and tighten bolts. AT
쐌 Use genuine anaerobic liquid gasket, Three Bond TB1215,
Loctite Part No. 51813 or equivalent.

PD

AX
SMT343A

7. Install snap ring to 2-4 shift rod.

SU

BR

ST

RS
SMT272A

8. Install oil gutter and oil cover. BT

9. Apply ATF to each part in center case.

HA

SC

EL
SMT344A
IDX
TF-35
 ASSEMBLY

10. Apply sealant to mating surface of rear case then attach it to

center case and tighten bolts.
쐌 Use genuine anaerobic liquid gasket, Three Bond TB1215,
Loctite Part No. 51813 or equivalent.
11. Install 4WD switch.
쐌 Apply sealant to switch threads.
쐌 Use genuine anaerobic liquid gasket, Three Bond TB1215,
Loctite Part No. 51813 or equivalent.

SMT497C

12. Install the companion flange and the companion flange nut.
쐌 Tighten the companion flange to specification. Refer to
“Gear Components”, TF-13.

WTF003

TF-36
 SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications

General Specifications NGTF0035

Transfer model TX10A GI

High 1.000
Gear ratio
Low 2.020 MA
Main gear 29

Low gear 37 EM
High 38
Number of teeth Counter gear
Low 24 LC
Front drive sprocket 41

Front drive shaft 41 EC

Fluid capacity
(US qt, Imp qt) 2.2 (2-3/8, 2)

Inspection and Adjustment FE

NGTF0040
CLEARANCE BETWEEN FRONT DRIVE SPROCKET AND 2-4 COUPLING SLEEVE NGTF0040S01
Unit: mm (in) CL
Allowable clearance ″C″ 0.2 - 0.54 (0.008 - 0.0213)

MT
GEAR END PLAY NGTF0040S02
Unit: mm (in)

Front drive sprocket 0.2 - 0.35 (0.008 - 0.0138) AT

Low gear 0.2 - 0.35 (0.008 - 0.0138)

Counter gear 0 - 0.2 (0 - 0.008)

CLEARANCE BETWEEN BAULK RING AND CLUTCH GEAR NGTF0040S03

Unit: mm (in)
PD
Standard Wear limit

1.0 - 1.5 (0.039 - 0.059) 0.5 (0.020)

AX

Available Shim NGTF0040S04 SU

COUNTER GEAR REAR BEARING NGTF0040S0401

Allowable clearance 0 - 0.2 mm (0 - 0.008 in)

BR
Thickness mm (in) Part No.*

0.1 (0.004) 33112-C6900

0.2 (0.008) 33112-C6901
ST
0.3 (0.012) 33112-C6902
0.4 (0.016) 33112-C6903
0.5 (0.020) 33112-33G00 RS
0.6 (0.024) 33112-33G01

*: Always check with the Parts Department for the latest parts information.
BT

HA

SC

EL

IDX
TF-37
 SERVICE DATA AND SPECIFICATIONS (SDS)
Available Snap Ring

Available Snap Ring NGTF0040S05

MAINSHAFT FRONT BEARING NGTF0040S0501

Allowable clearance 0 - 0.15 mm (0 - 0.0059 in)

Thickness mm (in) Part No.*

3.10 (0.1220) 33138-73P10

3.19 (0.1256) 33138-73P11
3.28 (0.1291) 33138-73P12

*: Always check with the Parts Department for the latest parts information.

MAIN GEAR BEARING NGTF0040S0502

Allowable clearance 0 - 0.15 mm (0 - 0.0059 in)

Thickness mm (in) Part No.*

2.60 (0.1024) 33114-73P00

2.69 (0.1059) 33114-73P01
2.78 (0.1094) 33114-73P02

*: Always check with the Parts Department for the latest parts information.

MAINSHAFT REAR BEARING NGTF0040S0503

Allowable clearance 0 - 0.15 mm (0 - 0.0059 in)

Thickness mm (in) Part No.*

1.80 (0.0709) 33138-73P20

1.89 (0.0744) 33138-73P21
1.98 (0.0780) 33138-73P22
2.07 (0.0815) 33138-73P23
2.16 (0.0850) 33138-73P24

*: Always check with the Parts Department for the latest parts information.

TF-38