DISASSEMBLY AND REASSEMBLY



Disassembly steps

>>F<<
 1.
 Snap ring
<<A>>
2.
 Clutch hub (H-L)
<<A>>
3.
 Low speed gear


4.
 Bearing spacer


5.
 Needle bearing
<<B>>
 >>E<<
 6.
 Lock nut
<<C>>
 >>D<<
 7.
 Ball bearing


8.
 Oil guide


9.
 Sprocket spacer


10.
 Steel ball


11.
 Drive sprocket


12.
 Needle bearing


13.
 Sprocket sleeve


14.
 Steel ball

>>C<<
 15.
 Clutch sleeve
<<D>>
 >>B<<
 16.
 Clutch hub (2-4WD)
<<D>>
 >>A<<
 17.
 Stopper plate
<<D>>
 >>A<<
 18.
 Ball bearing


19.
 Rear output shaft

DISASSEMBLY SERVICE POINTS

<<A>> CLUTCH HUB (H-L) /LOW SPEED GEAR REMOVAL

1.Use special tool Remover (MD998801) so that load may received by the low speed gear.
2.Use a press to push the front end of the rear output shaft, and then remove the clutch hub and low speed gear.

<<B>> LOCK NUT REMOVAL

1.Remove the lock nut from the shaft.

2.Hold the drive sprocket in a soft-jaw vice.
3.Shift the clutch sleeve to the drive sprocket side.
4.Use special tool Lock nut wrench (MD998835) to remove the lock nut.

<<C>> BALL BEARING REMOVAL

1.Use special tool Remover (MD998801) to support the ball bearing.
2.Use a press to push at a rear end of the rear output shaft, and then remove the radial ball bearing.
note
    The bearing may fit loosely on the shaft, so that removal is possible without using a press.

<<D>> CLUTCH HUB (2-4WD) / STOPPER PLATE / BALL BEARING REMOVAL

1.Place special tool Remover (MD998801) so that the load is applied at the bearing.
2.Use a press to push at the rear end of the rear output shaft, and then remove the clutch hub, stopper plate and ball bearing.
note
    The clutch hub may fit loosely on the shaft, so that removal is possible without using a press.

REASSEMBLY SERVICE POINTS

>>A<< BALL BEARING / STOPPER PLATE INSTALLATION

1.Fit the ball bearing and stopper plate onto the rear output shaft.
2.Use special tools to press in the ball bearing.

  • Remover (MD998801)
  • Installer cap (MD998812)
  • Installer-100 (MD998813)
  • Installer-200 (MD998814)
  • Installer adapter (60) (MD998829)

>>B<< CLUTCH HUB (2-4WD) INSTALLATION

1.Confirm the clutch hub installation direction, and fit onto the rear output shaft.
2.Use special tools press in the clutch hub.

  • Remover (MD998801)
  • Installer cap (MD998812)
  • Installer-100 (MD998813)
  • Installer-200 (MD998814)
  • Installer adapter (44) (MD998821)
note
    The clutch hub may fit loosely on the shaft, so that installation is possible without using a press.

>>C<< CLUTCH SLEEVE INSTALLTION

Check that the clutch sleeve is in the correct direction for installation.

>>D<< BALL BEARING INSTALLATION

Use special tools to install the ball bearing.

  • Remover (MD998801)
  • Installer cap (MD998812)
  • Installer-200 (MD998814)
  • Installer adapter (44) (MD998821)
note
    The ball bearing may be fitted loosely on the shaft, so that installation is possible without using a press

>>E<< LOCK NUT INSTALLTION

1.Hold the drive sprocket in a soft-jaws vice.
2.Shift the clutch sleeve to the drive sprocket side.
3.Using special tool Lock nut wrench (MD998835) tighten the lock nut to the specified torque of 113 ± 14 N·m.

4.Stake the two places of the lock nut as shown in illustration.

>>F<< SNAP RING INSTALLATION

1.Install the thickest snap ring that can be fitted in the snap ring groove of the rear output shaft.
2.Make sure that the H-L clutch hub axial play meets the standard value.
Standard value: 0 - 0.08 mm