1. Remove the 4 case bolts.
2. Remove the right carrier case half.
3. Clean the sealing surfaces on the carrier case halves. Remove all oil and grease using a chlorinated solvent, such as carburetor cleaner.

Tools Required

1. Apply a bead of sealer to one carrier half mounting surface.
2. Assemble the carrier halves.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

3. Install the carrier halves assembly bolts.

Tighten
Tighten the bolts to 50 N·m (37 lb ft).

4. Ensure that the sleeves are positioned properly, as previously marked.



5. Install the bolts and lock tabs.

Tighten
Tighten the bolts to 8 N·m (71 lb in).

6. Clean all oil and grease from the left cover and seal assembly, the bolts and the carrier sealing surfaces using carburetor cleaner or equivalent.
7. Apply sealer to the cover.
8. Install the left cover and seal assembly.

Tighten
Tighten the bolts to 25 N·m (18 lb ft).




9. Install the bearing using the J 42211 and the J 8092 .



10. Install the shaft seal using the J 23911 .



11. Install the shift housing seal using the J 33799 .



12. Install the clutch shaft pilot bearing using the J 33842 .
13. Install the washer to the clutch shaft.
14. Install the clutch shaft to the carrier assembly.
15. Install the clutch sleeve.
16. Install the thrust washer using grease in order to secure.
17. Install the spring with the shift shaft and fork.



18. Install the thrust washer using grease in order to secure. Align the notch and tab.
19. Install the inner axle shaft to the housing.
20. Install the clutch gear with the retaining ring. Tap into place.

20.1.

Remove all oil and grease from the housing flange to carrier gasket surfaces using carburetor cleaner or equivalent.

20.2.

Apply sealer to the carrier.

21. Install the shaft and housing assembly to the carrier.
22. Install the two upper bolts finger-tight.
23. Install the shift cable housing and the remaining bolts.

Tighten
Tighten the five bolts to 48 N·m (36 lb ft).




24. Install the bushings using the J 33791 -1, the J 33791-2 and the J 33791-3.

Tools Required

J 33798 Hub Engagement Tool

1. Inspect the operation of the shift mechanism. Insert the J 33798 into the shift fork.
2. Turn the axle shaft while engaging and disengaging the shift mechanism with the tool.
3. The mechanism should operate smoothly. If not, remove the tube. Inspect for damaged or improperly installed parts.