Part 1 of 2

ASSEMBLY





1. Install revolution sensor onto transmission case.
- Always use new sealing parts.








2. Install differential side oil seals on transmission case and converter housing, so that "A" and "B" are within specifications.





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





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





5. 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. Tighten transmission case fixing bolts (A) and (B) to the specified torque.





5. Attach dial indicator on differential case at transmission case side.
6. Insert Tool into differential side gear from converter housing.
7. Move Tool up and down and measure dial indicator deflection.

Differential side bearing preload "T": 0.04 mm - 0.09 Nm (0.0016 in. - 0,0035 inch)

8. Select proper thickness of differential side bearing adjusting shim(s) using image as a guide.





Differential side bearing adjusting shim: Refer to image.





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 image on transmission case.
13. Reinstall converter housing on transmission case and tighten transmission case fixing bolts to the specified torque.





14. Insert Tool into differential case and measure turning torque of final drive assembly.
- Turn final drive assembly in both directions several times to seat bearing rollers correctly.

Turning torque of final drive assembly (New bearing): 0.49 - 1.08 Nm (5.0 - 11.0 kg-cm, 4.3 - 9.5 inch lbs.)

- 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 PINION GEAR BEARING PRELOAD





1. Remove transmission case and final drive assembly from converter housing.
2. Select proper thickness of reduction pinion gear bearing adjusting shim using the following procedures.
a. Place reduction pinion 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 - (13 + C)
"A": Distance between the surface of idler gear bearing inner race and the adjusting shim mating surface of reduction pinion gear.





- Measure dimension "B" between the end of reduction pinion 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 pinion gear and the adjusting shim mating surface of reduction pinion 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 idler gear.
- Measure dimension "E" in at least two places.

e. Calculate "T" and select proper thickness of reduction pin ion gear bearing adjusting shim using image as a guide.





T = A - E
Reduction pinion gear bearing adjusting shim: Refer to image.





3. Install reduction pinion gear and reduction pinion 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 pinion gear.
- Press idler gear so that idler gear can be locked by parking pawl.





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

Turning torque of reduction pinion gear: 0.11 - 0.69 Nm (1.1 - 7.0 kg-cm, 0.95 - 6.08 inch lbs.)

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 "e1," and "e2" at side cover and then calculate dimension "A".
- Measure dimension "e1," and "e2" in at least two places.

"A": Distance between transmission case fitting surface and adjusting shim mating surface.
A= e1, - e2 e2: Height of gauge





5. Measure dimensions "e2" and "e3" and then calculate dimension "B".
- Measure "e2" and "e3" 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 = e2 - e3 e2: 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 - 0.5 Nm (0 - 0.020 inch)

Output shaft end play adjusting shim: Refer to images.

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.
- Apply locking sealant to the mating surface of transmission case.





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

ASSEMBLY 2





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.





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.





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.