Part 1

TRANSMISSION ASSEMBLY


Assembly






1. As shown in the figure, use a drift [22 mm (0.87 in) dia. commercial service tool] to drive manual shaft oil seals into the transmission case until it is flush.

CAUTION:
- Never reuse manual shaft oil seals.
- Apply ATF to manual shaft oil seals.





2. Install detent spring and spacer in transmission case. Tighten detent spring and spacer bolt to the specified torque.





3. Install manual shaft to transmission case.





4. Install parking rod to manual plate.





5. Install manual plate (with parking rod) to manual shaft.





6. Install retaining pin into the manual plate and manual shaft.
a. Fit pinhole of the manual plate to pinhole of the manual shaft with a pin punch.
b. Use a hammer to tap the retaining pin into the manual plate.

CAUTION:
Drive retaining pin to 2�0.5 mm (0.08�0.020 in) over the manual plate.





7. Install retaining pin into the transmission case and manual shaft.
a. Fit pinhole of the transmission case to pinhole of the manual shaft with a pin punch.
b. Use a hammer to tap the retaining pin into the transmission case.

CAUTION:
Drive retaining pin to 5�1 mm (0.20�0.04 in) over the transmission case.





8. Install O-rings to servo assembly.





9. Install return spring to servo assembly.





10. Install servo assembly to transmission case.





11. Install snap ring to transmission case with a pair of snap ring pliers.





12. Install D-rings to reverse brake piston.





13. Install reverse brake piston to transmission case.





14. Install needle bearing to drum support edge surface.

CAUTION:
Check the direction of needle bearing. Location of Adjusting Shims, Needle Bearings, Thrust Washers and Snap Rings.





15. Install seal rings to drum support.





16. Install spring retainer and return spring to transmission case.





17. Set the SST on spring retainer and install snap ring (fixing spring retainer) to transmission case while compressing return spring.

CAUTION:
Securely assemble them with a flat-bladed screwdriver so that snap ring tension is slightly weak.





18. Install reverse brake drive plates, driven plates, dish plates, retaining plate and snap ring to transmission case.

1 : Snap ring
2 : Retaining plate
3 : Drive plate
4 : Driven plate
5 : Dish plate
6/6 : Drive plate / Driven plate

CAUTION:
Check order of plates.





19. Assemble N-spring.
20. Install reverse brake retaining plate to transmission case.





21. Install snap ring to transmission case.





22. Measure clearance between retaining plate and snap ring. If not within specified clearance, select proper retaining plate.

Specified clearance "A"
Standard: TM-276, "Reverse Brake". Reverse Brake
Retaining plate: Refer to TM-276, "Reverse Brake". Reverse Brake





23. Install needle bearing to transmission case.

CAUTION:
Check the direction of needle bearing. Location of Adjusting Shims, Needle Bearings, Thrust Washers and Snap Rings.





24. Install output speed sensor (1) to transmission case. Tighten bolt ( ) to the specified torque.

CAUTION:
- Never subject it to impact by dropping or hitting it.
- Never disassemble.
- Never allow metal filings, etc. to get on the sensor's front edge magnetic area.
- Never place in an area affected by magnetism.





25. As shown in the figure, use the drift to drive rear oil seal into the rear extension (2WD) or adapter case (AWD) until it is flush.

CAUTION:
- Never reuse rear oil seal.
- Apply ATF to rear oil seal.





26. Install return spring (1) to parking pawl (2).





27. Install parking pawl (with return spring) and pawl shaft to rear extension (2WD) or adapter case (AWD).





28. Install parking actuator support to rear extension (2WD) or adapter case (AWD).





29. Install needle bearing (1) to rear extension (2WD) or adapter case (AWD).

CAUTION:
Check the direction of needle bearing. Location of Adjusting Shims, Needle Bearings, Thrust Washers and Snap Rings.
30. Install rear extension assembly (2WD) or adapter case assembly (AWD) according to the following procedures.
a. 2WD

i. Install seal rings (1) to output shaft.





ii. Install parking gear (1) to output shaft (2).





iii. Install output shaft to transmission case.

CAUTION:
Be careful not to mistake front for rear because both sides looks similar. (Thinner end is front side.)





iv. Install bearing race to output shaft.





v. Apply recommended sealant (Genuine Anaerobic Liquid Gasket or equivalent. Fluid Type Specifications.) to rear extension assembly as shown in the figure.

A : Start and finish point shall be in the center of two bolts.
B : 3 - 5 mm (0.12 - 0.20 in)
Sealant width (C) : 1.0 - 2.0 mm (0.04 - 0.08 in)
Sealant height (C) : 0.4 - 1.0 mm (0.016 - 0.04 in)

CAUTION:
Completely remove all moisture, oil and old sealant, etc. from the transmission case and rear extension assembly mounting surfaces.





vi. Install rear extension assembly to transmission case.

CAUTION:
Insert the tip of parking rod between the parking pawl and the parking actuator support when assembling the rear extension assembly.





vii. Tighten rear extension assembly bolts to the specified torque.

1 : Self-sealing bolt
A : Bolt

b. AWD i. Install seal rings (1) to output shaft.





ii. Install parking gear (1) to output shaft (2).





iii. Install output shaft in transmission case.

CAUTION:





Be careful not to mistake front for rear because both sides looks similar. (Thinner end is front side.)





iv. Install bearing race to output shaft.





v. Install gasket onto transmission case.

CAUTION:
- Completely remove all moisture, oil and old gasket, etc. from the transmission case and adapter case assembly mounting surfaces.
- Never reuse gasket.





vi. Install adapter case assembly to transmission case.

CAUTION:
Insert the tip of parking rod between the parking pawl and the parking actuator support when assembling the adapter case assembly.





vii. Tighten adapter case assembly bolts (1) to the specified torque.
[With bracket (2).]

3 : Self-sealing bolt
Black arrow: Bolt





31. Install needle bearing in drum support.

CAUTION:
Check the direction of needle bearing. Location of Adjusting Shims, Needle Bearings, Thrust Washers and Snap Rings.





32. Install direct clutch assembly in reverse brake.

CAUTION:
Make sure that drum support edge surface and direct clutch inner boss edge surface come to almost same place.





33. Install high and low reverse clutch assembly in direct clutch.





34. Align the drive plate with a flat-bladed screwdriver.





35. Install high and low reverse clutch hub, mid sun gear assembly and rear sun gear assembly as a unit.

CAUTION:





Make sure that portion "A" of high and low reverse clutch drum protrudes approximately 2 mm (0.08 in) beyond portion "B" of rear sun gear.





36. Install needle bearing to rear carrier assembly.

CAUTION:
Check the direction of needle bearing. Location of Adjusting Shims, Needle Bearings, Thrust Washers and Snap Rings.





37. Install bearing race to rear carrier assembly.

CAUTION:
Check the direction of needle bearing. Location of Adjusting Shims, Needle Bearings, Thrust Washers and Snap Rings.





38. Install rear carrier assembly to direct clutch drum.





39. Install needle bearing (rear side) to mid carrier assembly.

CAUTION:
Check the direction of needle bearing. Location of Adjusting Shims, Needle Bearings, Thrust Washers and Snap Rings.





40. Install needle bearing (front side) to mid carrier assembly.

CAUTION:
Check the direction of needle bearing. Location of Adjusting Shims, Needle Bearings, Thrust Washers and Snap Rings.