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1. Remove the cap screws securing the pinion hous-
ing. Account for the coupler, fork, and spring.
KX222
4. Install the input shaft into the housing; then install
the front boot and secure with an appropriate boot
clamp and the rear boot with an appropriate boot KX209
clamp. 2. Remove the cap screws securing the gear case
cover. Account for and make note of the ID tag
location for assembling purposes.
CD112
5. Using a new O-ring lubricated with grease, install
the front drive actuator and secure with the cap
6
KX173
screws. 3. Using a plastic mallet, tap lightly to remove the
differential cover. Account for an O-ring.
6. Place the pinion housing with new gasket onto the
gear case housing; then secure with the existing NOTE: If the cover is difficult to remove, pry on
cap screws. Tighten to 23 ft-lb. the cover in more than one recessed location.
NOTE: If a new gear case housing is being 4. Remove the left gear case bearing flange assembly
installed, tighten the cap screws to 28 ft-lb. and account for a shim. Mark the shim as left-side.
CD103 KX177
Disassembling Pinion Gear
NOTE: This procedure can be performed on a
rear gear case.
6-7