Speed Sensor Rectification Procedure
CAUTION:It is vital to ensure a clean working area and to protect against external contamination of the transmission and transmission fluid.
1. Drive the vehicle onto a lift.
2. Refer to RAVE/GTR section 86.15.11 and remove the battery and battery carrier bracket.
3. Raise the vehicle.
4. Release the intermediate exhaust pipe from the front mounting rubber.
5. Remove the front skid plate from the vehicle.
6. If the vehicle is on a drive-on lift, raise the front of the vehicle to a wheels-free condition and support the body on two jack stands.
CAUTION:
The drained ATF will be reused. It is very important to use a clean storage container and maintain clean working conditions. Clean the container before each use and cover or seal the container during the procedure to prevent contamination.
7. Refer to RAVE/GTR section 44.24.02, JATCO, Gearbox Fluid - Drain & Refill, and drain the transmission fluid into a clean container.
8. Cover the container to prevent contamination and retain the fluid for refill.
9. Loosen the nut securing the gear selector cable to the gear linkage. (Arrowed in Figure 2)
10. Release the gear selector cable from the abutment bracket and remove the selector cable from the transmission. (Arrowed in Figure 3)
11. Remove the left-hand front wheel.
12. Remove the three bolts securing the left-hand front splash shield and remove the shield. (Figure 4)
CAUTION:
It is vital that the through-bolt securing the left hand engine mount to the transmission is not removed from the bracket until a transmission jack is in place.
13. Loosen, but do not remove the through-bolt securing the left hand engine mount to the bracket on the transmission. (Figure 5)
14. Raise the lift.
15. Position a transmission jack under the transmission to support the engine without exerting any load onto the transmission mounting.
16. Remove the through-bolt securing the left hand engine mounting to the bracket on the transmission. (Arrowed in Figure 5)
17. Lower the transmission to gain access to the transmission side cover.
18. Ensure the area around the side cover is clean and free from debris.
19. Remove 16 bolts securing the side cover to the transmission. (Arrowed in Figure 6)
20. Remove and discard the 0 rings from two M10 bolts.
NOTE:
Slight pressure with a pry bar may be required to release the side cover. (Figure 7)
21. Release and remove the transmission side cover.
CAUTION:
The reverse clutch drum must remain fully fitted and in position during this process. (Arrowed in Figure 8)
22. Maintain the reverse clutch drum in position.
23. Release and remove the bearing race from the side cover and place aside. (Figure 9).
24. Disconnect the multi-plug from the speed sensor. (Arrowed in Figure 10)
25. Remove two bolts from the speed sensor securing bracket. (Arrowed in Figure 11)
26. Remove the bracket.
27. Remove the speed sensor and discard.
28. Remove the 2nd - 4th gear brake return spring. (Arrowed in Figure 12)
29. Remove and discard the lip seal from the transmission casing. (Arrowed in Figure 13)
30. Place a lint-free cloth over the reverse clutch drum and the inner part of the transmission to protect from dust and debris. (Figure 14)
CAUTION:
All of the existing sealant must be removed prior to assembly without damage to the sealing surface.
^ Contamination must be prevented from entering the transmission.
^ A razor blade or other fine cleaning tool should be used.
^ Use of a power sander or abrasives will damage the sealing surface and create contaminating debris.
31. Carefully clean the side cover and the mating face of the transmission.
32. Remove the Teflon rings from the side cover and discard. (Figure 15)
CAUTION:
Use of "Petroleum Jelly" is vital to the successful repair of the transmission. Use of other lubricants or grease can lead to contamination and serious consequences.
33. Install the new Teflon rings to the side cover and apply petroleum jelly ensuring that the Teflon rings are fitted in position. (Arrowed in Figure 15)
34. Remove the lint-free cloth.
35. Apply petroleum jelly to a new lip seal and install the lip seal to the transmission casing. (Figure 16)
CAUTION:
the 2nd - 4th gear brake return spring must be properly oriented for the speed sensor. There is a gap in the ring that will allow the speed sensor to be positioned.
36. Install the 2nd - 4th gear brake return spring.
37. Install the new speed sensor supplied in repair kit TGM5000070K.
38. Install the sensor retaining bracket.
39. Secure the bracket with previously removed bolts and tighten to 8 Nm (6 lbf.ft).
40. Connect the multi-plug to the speed sensor.
NOTE:
The transmission must be fully drained before the new sealant is applied to the mating surfaces. Sealant exposed to transmission fluid will not cure properly and the bond between the casings may be weak resulting in leakage.
41. Apply a continuous bead of sealant (supplied in kit TGM5OOO7OK) to the clean side cover mating face.
42. Ensure the bearing race is clean, apply petroleum jelly to the bearing race and position to side cover (Figure 17).
43. Install new 0 rings to the M10 side cover retaining bolts.
44. Ensure transmission mounting surface is clean and free of fluid.
45. Position the side cover to the transmission.
46. Start and tighten securing bolts evenly and progressively to ensure the side cover remains parallel to the transmission.
47. Torque M8 bolts to 21 Nm (15 lbf.ft) and M1O bolts to 36 Nm (27 lbf.ft).
48. Raise the transmission and install the left hand engine mounting through-bolt.
49. Tighten the through-bolt until snug.
50. Lower and remove the transmission jack.
51. Install the splash shield and tighten bolts to 10 Nm (7 lbf.ft).
52. Install the road wheel.
53. Position the gear selector cable to the gear linkage.
54. Position the gear selector cable and secure to the abutment bracket.
55. Refer to RAVE/GTR section 44.30.04 and adjust the selector cable.
56. If using a drive-on lift, raise the front of the vehicle, remove the jack stands and lower the vehicle onto ramp.
57. Connect the exhaust mounting.
58. Install the front skid plate and tighten body bolts to 45 Nm (33 lbf.ft) and rear screws to 8 Nm (6 lbf.ft).
59. Lower the vehicle lift.
60. Tighten the through-bolt on the engine mount to 100 Nm (74 lbf.ft).
61. Refer to RAVE/GTR section 86.15.11 and install the battery carrier bracket.
62. Install battery and connect observing Workshop Manual precautions.
CAUTION:
It is vital that the proper fluid level is obtained and that the check and top-up procedure is performed.
63. Refer to Workshop Manual, RAVE/GTR section 44.24.02 and perform the following:
^ Fill the transmission with the saved fluid.
^ Top up with Texaco ATF N402 (LRN402).