Part 2

6. Select proper thickness of adjusting shim so that output shaft end play (clearance between side cover and output shaft bearing) is within specifications.

Output shaft end play (A - B): 0 - 0.5 mm (0 - 0.020 in.)
Output shaft end play adjusting shim: Refer to Specifications.




7. Install adjusting shim on output shaft bearing.




8. Apply locking sealant to transmission case as shown in illustration.
9. Install side cover on transmission case and tighten fixing bolt to the specified torque.
- Apply locking sealant to the mating surface of transmission case.

ASSEMBLY




1. Remove paper rolled around bearing retainer.
2. Install thrust washer on bearing retainer.
- Apply petroleum jelly to thrust washer.




3. Install forward clutch assembly.
- Align teeth of low & reverse brake drive plates before installing.
- Make sure that bearing retainer seal rings are not spread.

RL4F03A



4. Install bearing race on bearing retainer.
- Apply petroleum jelly to bearing race.




5. Install needle bearings on rear internal gear.
- Apply petroleum jelly to needle bearings.
- Pay attention to direction of needle bearing.

RL4F03V



4. Install thrust needle bearing on bearing retainer.
- Apply petroleum jelly to thrust bearing.
- Pay attention to direction of thrust needle bearing.




5. Install thrust needle bearing on rear internal gear.
- Apply petroleum jelly to thrust needle bearing.
- Pay attention to direction of thrust needle bearing.


RL4F03A & F03V



6. Hold forward clutch hub and turn overrun clutch hub. Check overrun clutch hub for directions of lock and unlock.
- If not as shown in illustration, check installed direction of forward one-way clutch.




7. Install rear internal gear assembly.
- Align teeth of forward clutch and overrun clutch drive plate.




8. Install needle bearing on rear planetary carrier.
- Apply petroleum jelly to needle bearing.
- Pay attention to direction of needle bearing.




9. Install rear sun gear on rear planetary carrier.
- Pay attention to direction of rear sun gear.




10. Install rear planetary carrier on transmission case.




11. Install thrust needle bearing on front planetary carrier.
- Apply petroleum jelly to thrust needle bearing.
- Pay attention to direction of thrust needle bearing.




12. Install low one-way clutch to front planetary carrier by turning it in the direction of the arrow as shown.
13. While holding front planetary carrier, turn low one-way clutch.
Check low one-way clutch for correct directions of lock and unlock.




14. Install front planetary carrier assembly on transmission case.




15. Install snap ring with screwdriver.
- If forward clutch and bearings are not installed correctly, snap ring will not fit groove of transmission case.




16. Install needle bearing on front sun gear.
- Apply petroleum jelly to needle bearing.
- Pay attention to direction of needle bearing.




17. Install front sun gear on front planetary carrier.




18. Install needle bearing on front sun gear.
- Apply petroleum jelly to needle bearing.
- Pay attention to direction of needle bearing.




19. Install high clutch hub on front sun gear.




20. Install needle bearing on high clutch hub.
- Apply petroleum jelly to needle bearing.
- Pay attention to direction of needle bearing.




21. Remove paper rolled around input shaft.
22. Install input shaft assembly.
- Align teeth of high clutch drive plates before installing.




23. Install reverse clutch assembly.
- Align teeth of reverse clutch drive plates before installing.


ADJUSTMENT




When any parts listed in the table are replaced, total end play or reverse clutch end play must be adjusted.


TOTAL END PLAY



- Measure clearance between reverse clutch drum and needle bearing for oil pump cover.
- Select proper thickness of bearing race so that end play is within specifications.




1. Measure dimensions "K" and "L" and then calculate dimension "J".




a. Measure dimension "K".




b. Measure dimension "L".
c. Calculate dimension "J".

"J": Distance between oil pump fitting surface of transmission case and needle bearing mating surface of high clutch drum.

J = K - L




2. Measure dimension "M".
a. Place bearing race and needle bearing on oil pump assembly.




b. Measure dimension "M".

"M": Distance between transmission case fitting surface and needle bearing on oil pump cover.
M(1): Indication of gauge.




c. Measure thickness of straightedge "t".

M = M(1) - t

3. Adjust total end play "T(3)".

T(3) = J - M
Total end play "T(3)": 0.25 - 0.55 mm (0.0098 - 0.0217 in.)

- Select proper thickness of bearing race so that total end play is within specifications.

Bearing races: Refer to Specifications.


REVERSE CLUTCH END PLAY



- Measure clearance between oil pump cover and thrust washer for reverse clutch drum.
- Select proper thickness of thrust washer so that end play is within specifications.




1. Measure dimensions "O" and "P" and then calculate dimension "N".




a. Place thrust washer on reverse clutch drum.
b. Measure dimension "O".




c. Measure dimension "P".
d. Calculate dimension "N".

"N": Distance between oil pump fitting surface of transmission case and thrust washer on reverse clutch drum.
N = O - P




2. Measure dimensions "R" and "S" and then calculate dimension "Q".




a. Measure dimension "R".





b. Measure dimension "S".
c. Calculate dimension "Q".

"Q": Distance between transmission case fitting surface and thrust washer mating surface.
Q = R - S

3. Adjust reverse clutch end play "T(4)".

T(4) = N - Q
Reverse clutch end play: 0.65 - 1.00 mm (0.0256 - 0.0394 in.)

- Select proper thickness of thrust washer so that reverse clutch end play is within specifications.

Thrust washer: Refer to Specifications.


ASSEMBLY




1. Remove reverse clutch assembly and install needle bearing on high clutch assembly.
- Pay attention to direction of needle bearing.

2. Install reverse clutch assembly.




3. Install anchor end pin, washer and lock nut on transmission case.
4. Place brake band on periphery of reverse clutch drum. Then, tighten anchor end pin just enough so that brake band is fitted on periphery of reverse clutch drum uniformly.




5. Place bearing race selected in total end play adjustment step on oil pump cover.
- Apply petroleum jelly to bearing race.




6. Place thrust washer selected in reverse clutch end play step on reverse clutch drum.
- Apply petroleum jelly to thrust washer.




7. Install oil pump assembly on transmission case.




8. Tighten oil pump fixing bolts to specified torque.




9. Install O-ring to input shaft.
- Apply A.T.F. to O-ring.




10. Adjust brake band.
a. Tighten anchor end pin to specified torque.

Anchor end pin:
Tightening Torque: 4 - 6 N.m (0.4 - 0.6 kg-m, 2.9 - 4.3 ft-lb)




b. Back off anchor end pin two and a half turns.




c. While holding anchor end pin, tighten lock nut.




11. Apply compressed air to oil holes of transmission case and check operation of brake band.