Disassembly
1. Remove nut of companion flange.
2. Remove companion flange.
3. Remove 4WD switch.
4. Remove rear case. Be careful not to damage the mating surface.
5. Remove oil cover and oil gutter.
6. Remove snap ring from 2 - 4 shift rod.
7. Remove bolts securing bearing retainer. This step is necessary to remove mainshaft from center case.
8. Remove bolts securing center case to front case and then separate center case and front case.
9. Measure end play of low gear.
Standard: 0.2 - 0.35 mm (0.0079 - 0.0138 inch)
If end play is beyond the maximum value, check low gear and L & H hub for wear.
10. Disassemble center case assembly.
a. Remove snap ring from mainshaft.
b. Remove low gear with L & H hub.
c. Remove needle bearing of main shaft.
d. Make sure of the direction of the drive chain before removing it. (It must be reinstalled in the same direction.)
e. Remove mainshaft, front drive and drive chain as a set by tapping front end of mainshaft and front drive shaft alternately. Be careful not to bend drive chain.
11. Disassemble front case assembly.
a. Remove switch, plugs, check springs and check balls.
b. Remove lock pin from outer shift lever, then remove lever.
c. Remove lock pin of inner shift lever and drive out cross shaft with plug.
d. Remove 2-4 shift rod.
e. Remove L & H shift rod and fork assembly with coupling sleeve.
f. Remove needle bearing from main gear.
g. Remove bolts securing front case cover and then remove case.
h. Remove counter gear by tapping lightly.
i. Remove main gear by tapping lightly.