Part 5

OUTPUT SHAFT, IDLER GEAR, REDUCTION PINION GEAR AND BEARING RETAINER





DISASSEMBLY



1. Remove seal rings from output shaft and bearing retainer.




2. Remove output shaft bearing with screwdrivers.
- Always replace bearing with a new one when removed.
- Do not damage output shaft.




3. Remove snap ring from bearing retainer.




4. Remove needle bearing from bearing retainer.




5. Remove idler gear bearing inner race from idler gear.




6. Remove idler gear bearing outer race from transmission case.




7. Press out reduction pinion gear bearing from reduction pinion gear.




8. Remove reduction pinion gear bearing outer race from transmission case.


INSPECTION

Output Shaft, Idler Gear And Reduction Pinion Gear
- Check shafts for cracks, wear or bending.
- Check gears for wear, chips and cracks.

Bearing



- Make sure bearings roll freely and are free from noise, cracks, pitting or wear.
- When replacing taper roller bearing, replace outer and inner race as a set.

Seal Ring Clearance



- Install new seal rings to output shaft.
- Measure clearance between seal ring and ring groove of output shaft.

Standard clearance: 0.10 - 0.25 Nm (0.0039 - 0.0098 inch)
Allowable limit: 0.25 Nm (0.0098 inch)

- If not within allowable limit, replace output shaft.
- Install new seal rings to bearing retainer.
- Measure clearance between seal ring and ring groove of bearing retainer.

Standard clearance: 0.10 - 0.25 Nm (0.0039 - 0.0098 inch)
Allowable limit: 0.25 Nm (0.0098 inch)

- If not within allowable limit, replace bearing retainer.


ASSEMBLY



1. Press reduction pinion gear bearing on reduction pinion gear.




2. Install reduction pinion gear bearing outer race on transmission case.




3. Press idler gear bearing inner race on idler gear.




4. Install idler gear bearing outer race on transmission case.




5. Press output shaft bearing on output shaft.




6. Press needle bearing on bearing retainer.




7. Install snap ring to bearing retainer.




8. After packing ring grooves with petroleum jelly, carefully install new seal rings on output shaft and bearing retainer.




- Roll paper around seal rings to prevent seal rings from spreading.


BAND SERVO PISTON ASSEMBLY





DISASSEMBLY



1. Remove band servo piston snap ring.




2. Apply compressed air to oil hole in transmission case to remove OD servo piston retainer and band servo piston assembly.
- Hold band servo piston assembly with a rag or nylon waste.




3. Apply compressed air to oil hole in OD servo piston retainer to remove OD servo piston from retainer.
- Hold OD servo piston while applying compressed air.




4. Remove D-ring from OD servo piston.




5. Remove O-rings from OD servo piston retainer.




6. Remove band servo piston assembly from servo piston retainer by pushing it forward.




7. Place piston stem end on a wooden block. While pushing servo piston spring retainer down, remove E-ring.




8. Remove OD servo return spring, band servo thrust washer and band servo piston stem from band servo piston.




9. Remove 0-rings from servo piston retainer.




10. Remove D-rings from band servo piston.


INSPECTION

Pistons, Retainers And Piston Stem



- Check frictional surfaces for abnormal wear or damage.

Return Springs



- Check for deformation or damage. Measure free length and outer diameter.




Band servo inspection standard: Refer to image.


ASSEMBLY



1. Install D-rings to servo piston retainer.
- Apply ATF to 0-rings.
- Pay attention to position of each 0-ring.




2. Install band servo piston stem, band servo thrust washer, OD servo return spring and spring retainer to band servo piston.




3. Place piston stem end on a wooden block. While pushing servo piston spring retainer down, install E-ring.




4. Install O-rings to servo piston retainer.
- Apply ATF to O-rings.
- Pay attention to the positions of the O-rings.




5. Install band servo piston assembly to servo piston retainer by pushing it inward.




6. Install D-ring to OD servo piston.
- Apply ATF to D-ring.




7. Install O-rings to OD servo piston retainer.
- Apply ATF to O-rings.
- Pay attention to the positions of the O-rings.




8. Install OD servo piston to OD servo piston retainer.




9. Install band servo piston assembly and 2nd servo return spring to transmission case.
- Apply ATF to O-ring of band servo piston and transmission case.




10. Install OD servo piston assembly to transmission case.
- Apply ATF to 0-ring of band servo piston and transmission case.




11. Install band servo piston snap ring to transmission case.


FINAL DRIVE





DISASSEMBLY



1. Remove final gear.




2. Press out differential side bearings.




3. Remove speedometer drive gear.




4. Drive out pinion mate shaft retaining pin.




5. Draw out pinion mate shaft from differential case.
6. Remove pinion mate gears and side gears.