Assembly - Part 1

Assembly 1







1. Install differential side oil seals on transmission case and converter housing.




2. Install parking actuator support to transmission case.
- Pay attention to direction of parking actuator support.




3. Install parking pawl on transmission case and fix it with parking shaft.
4. Install return spring.

Adjustment 1

DIFFERENTIAL SIDE BEARING PRELOAD




1. Install differential side bearing outer race without adjusting shim on transmission case.
2. Install differential side bearing outer race on converter housing.




3. Place final drive assembly on transmission case.
4. Install transmission case on converter housing and tighten transmission case fixing bolts to the specified torque.




5. Set Tool on differential case at converter housing side and attach dial indicator on Tool.
6. Insert the other Tool viscous coupling from transmission case side.
7. Move Tool up and down and measure dial indicator deflection.
8. Select proper thickness of differential side bearing adjusting shim(s).

Suitable shim thickness = Dial indicator deflection + Specified bearing preload

Differential side bearing adjusting shim: Refer to Specifications. Specifications

Bearing preload: 0.05 - 0.09 mm (0.0020 - 0.0035 in)




9. Remove converter housing from transmission case.
10. Remove final drive assembly from transmission case.
11. Remove differential side bearing outer race from transmission case.
12. Reinstall differential side bearing outer race and shim(s) selected from Specifications on transmission case. Specifications
13. Reinstall converter housing on transmission case and tighten transmission case fixing bolts to the specified torque.




14. Insert Tool into viscous coupling and measure turning torque of final drive assembly.
- When measuring turning torque, turn final drive assembly in both directions several times to seat bearing rollers correctly.

Turning torque of final drive assembly (New bearing): 0.78 - 1.37 N.m (8.0 - 14.0 kg.cm, 6.9 - 12.2 in.lb)

- When old bearing is used again, turning torque will be slightly less than the above.
- Make sure torque is close to the specified range.

REDUCTION GEAR BEARING PRELOAD




1. Remove transmission case and final drive assembly from converter housing.
2. Select proper thickness of reduction gear bearing adjusting shim using the following procedures.
a. Place reduction gear on transmission case as shown.




b. Place idler gear bearing on transmission case.
c. Measure dimensions "B" "C" and "D" and calculate dimension "A".

A = D - (B + C)
"A": Distance between the surface of idler gear bearing Inner race and the adjusting shim mating surface of reduction gear.




- Measure dimension "B" between the end of reduction gear and the surface of transmission case.
- Measure dimension "B" in at least two places.




- Measure dimension "C" between the surface of idler gear bearing inner race and the surface of transmission case.
- Measure dimension "C" In at least two places.




- Measure dimension "D" between the end of reduction gear and the adjusting shim mating surface of reduction gear.
- Measure dimension "D" in at least two places.
- Calculate dimension "A".

A = D - (B + C)




d. Measure dimension "E" between the end of idler gear and the idler gear bearing inner race mating surface of idle gear. - Measure dimension "E" in at least two places.
e. Select proper thickness of reduction gear bearing adjusting shim.

Proper shim thickness = A - E - 0.5 mm (0.0020 in)* (* ... Bearing preload)
Reduction gear bearing adjusting shim: Refer to Specifications. Specifications




3. Install reduction gear and reduction gear bearing adjusting shim selected in step 2-e on transmission case.
4. Press idler gear bearing inner race on idler gear.
5. Press idler gear on reduction gear.
- Press Idler gear until idler gear fully contacts adjusting shim.




6. Tighten idler gear lock nut to the specified torque.
- Lock idler gear with parking pawl when tightening lock nut.




7. Measure turning torque of reduction gear.
- When measuring turning torque, turn reduction gear in both directions several times to seat bearing rollers correctly.

Turning torque of reduction gear: 0.05 - 0.39 N.m (0.5 - 4.0 kg.cm, 0.43 - 3.47 in.lb)

- If turning torque is out of specification, decrease or increase thickness of reduction gear bearing adjusting shim.




8. After properly adjusting turning torque, clinch idler gear lock nut as shown,

OUTPUT SHAFT END PLAY




- Measure clearance between side cover and the end of the output shaft bearing.
- Select proper thickness of adjusting shim so that clearance is within specifications.




1. Install bearing retainer for output shaft.




2. Install output shaft thrust needle bearing on bearing retainer.




3. Install output shaft on transmission case.




4. Measure dimensions "l1," and "l2" at side cover and then calculate dimension "A".
- Measure dimension "l1" and "l2" in at least two places.
"A": Distance between transmission case fitting surface and adjusting shim mating surface.
A = l1 - l3 l2: Height of gauge




5. Measure dimensions "l2" and "l3" and then calculate dimension "B".
Measure "C;" and "�3" in at least two places.
"B": Distance between the end of output shaft bearing outer race and the side cover fitting surface of transmission case.
B = l2 - l3 l2 Height of gauge




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 - 0.15 mm (0 - 0.0059 in)
Output shaft end play adjusting shim: Refer to Specifications. Specifications

7. Install adjusting shim on output shaft bearing.

Assembly 2




1. Apply locking sealant to transmission case as shown in illustration.




2. Set side cover on transmission case.




3. Tighten side cover fixing bolts to specified torque.
- Do not mix bolts (X) and (B).
- Always replace bolts (A) as they are self-sealing bolts.




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




6. Install forward clutch assembly.
- Align teeth of low & reverse brake drive plates before installing.
- Make sure that bearing retainer seal rings are not spread.
- If forward clutch assembly is correctly seated, points (1) and (2) are at almost same level.




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




8. Install overrun clutch hub.
- Apply petroleum jelly to thrust washers.
- Align teeth of overrun clutch drive plates before installing.




9. Hold forward clutch hub and turn rear internal gear.
Check overrun clutch hub for correct directions of lock and unlock.
- If not shown as illustration, check installed direction of forward one-way clutch.




10. Install forward clutch hub and rear internal gear assembly.
- Align teeth of forward clutch drive plates before installing.
- Check three hooks of thrust washer are correctly aligned after installing.
11. Install rear planetary carrier assembly and rear sun gear according to the following procedures.




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




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




c. Install rear planetary carrier on transmission case.




12. Install thrust needle bearing on front planetary carrier, then install them together on transmission case.
- Apply petroleum jelly to thrust needle bearing.
- Pay attention to direction of thrust needle bearing.
13. Install low and reverse brake piston according to the following procedures.




a. Set and align return springs to transmission case gutters as shown in illustration.




b. Set and align piston with retainer.




c. Install piston and retainer assembly on the transmission case.
- Align bracket to specified gutter as indicated In illustration.




d. Check that each protrusions of piston is correctly set to corresponding return spring as follows.
Push piston and retainer assembly evenly and confirm they move smoothly.
If they can not move smoothly, remove piston and retainer assembly and align return spring correctly as instructed in step "a".




e. Push down piston and retainer assembly and install snap ring.




14. Install low one-way clutch to front planetary carrier by turning carrier in the direction of the arrow shown.