Assembly 1

Assembly (1)





1. Install manual shaft components.
a. Install oil seal onto manual shaft.
- Apply ATF to oil seal.
- Wrap threads of manual shaft with masking tape.
b. Insert manual shaft and oil seal as a unit into transmission case.
c. Remove masking tape.





d. Push oil seal evenly and install it onto transmission case.





e. Align groove in shaft with retaining pin hole, then retaining pin into position as shown in figure at left.





f. Install detent spring and spacer.
g. While pushing detent spring down, install manual plate onto manual shaft.





h. Install lock nuts onto manual shaft.





2. Install accumulator piston.
a. Install O-rings onto accumulator piston.
- Apply ATF to O-rings.





Accumulator piston O-rings





b. Install return spring for accumulator A onto transmission case.
Free length of return spring: Refer to Specifications; Mechanical.





c. Install accumulator pistons A, B. C and D.
- Apply ATF to transmission case.





3. Install band servo piston.
a. Install return springs onto servo piston.





b. Install band servo piston onto transmission case.
- Apply ATF to O-ring of band servo piston and transmission case.
c. Install gasket for band servo onto transmission case.





d. Install band servo retainer onto transmission case.





4. Install rear side clutch and gear components.
a. Place transmission case in vertical position.





b. Slightly lift forward clutch drum assembly. Then slowly rotate it clockwise until its hub passes fully over clutch inner race inside transmission case.





c. Check to be sure that rotation direction of forward clutch assembly is correct.





d. Install thrust washer onto front of overrun clutch hub. Apply petroleum jelly to the thrust washer. Insert pawls of thrust washer securely into holes in overrun clutch hub.





e. Install overrun clutch hub onto rear internal gear assembly.





f. Install needle bearing onto rear of overrun clutch hub.
- Apply petroleum jelly to needle bearing.





g. Check that overrun clutch hub rotates as shown while holding forward clutch hub.





h. Place transmission case into horizontal position.





i. Install rear internal gear, forward clutch hub and overrun clutch hub as a unit onto transmission case.





j. Install needle bearing onto rear internal gear. Apply petroleum jelly to needle bearing.





k. Install bearing race onto rear of front internal gear.
- Apply petroleum jelly to bearing race.
- Securely engage pawls of bearing race with holes in front internal gear.





l. Install front internal gear on transmission case.





5. Install rear extension assembly on transmission case (2WD model only).
a. Install revolution sensor on rear extension.
b. Install rear extension gasket on transmission case.
c. Install parking rod on transmission case.
d. Install parking gear and needle bearing.
- Insert rear extension assembly into place while holding parking gear and needle bearing by hand.





6. Install output shaft and parking gear (4WD model only).
a. Insert output shaft from rear of transmission case while slightly lifting front internal gear. Do not force output shaft against front of transmission case.





b. Carefully push output shaft against front of transmission case. Install snap ring on front of output shaft.
- Check to be sure output shaft cannot be removed in rear direction.





c. Install needle bearing on transmission case. Pay attention to its direction-Black side goes to rear.
- Apply petroleum jelly to needle bearing.





d. Install parking gear on transmission case.





e. Install snap ring on rear of output shaft. Check to be sure output shaft cannot be removed in forward direction.





7. Install adapter case (4WD model only).
a. Install oil seal on adapter case.
- Apply ATF to oil seal.





b. Install O-ring on revolution sensor.
- Apply ATF to O-ring.
c. Install revolution sensor on adapter case.





d. Install adapter case gasket on transmission case.





e. Install parking rod on transmission case.





f. Install adapter case on transmission case.





8. Install front side clutch and gear components.
a. Install rear sun gear on transmission case.
- Pay attention to its direction.





b. Make sure needle bearing is on front of front planetary carrier.
- Apply petroleum jelly to needle bearing.
c. Make sure needle bearing is on rear of front planetary carrier.
- Apply petroleum jelly to bearing.
- Pay attention to its direction-Black side goes to front.





d. While rotating forward clutch drum clockwise, install front planetary carrier on forward clutch drum.





- Check that portion A of front planetary carrier protrudes approximately 2 mm (0.08 inch) beyond portion B of forward clutch assembly.





e. Make sure bearing races are on front and rear of clutch pack. Apply petroleum jelly to bearing races.
- Securely engage pawls of bearing races with holes in clutch pack.





f. Install clutch pack into transmission case.