Part 1 of 2

ASSEMBLY 1








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





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.

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 - (B + 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 pinion 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.)





8. After properly adjusting turning torque, clinch idler gear lock nut as shown (only RL4FO3V).

OUTPUT SHAFT BEARING PRELOAD





1. Select proper thickness of output shaft bearing adjusting spacer using the following procedures.
a. Remove paper rolled around output shaft.
b. Place bearing retainer on output shaft.





c. Place output gear bearing inner race on bearing retainer.
d. Measure dimensions "G" and "H" and calculate dimension "F".

"F": Distance between the surface of output gear bearing inner race and adjusting shim mating surface of output shaft.
F = H - G





- Measure dimension "G" between end of output shaft and surface of output gear bearing inner race.
- Measure in at least two places.





- Measure dimension "H" between end of output shaft and adjusting spacer mating surface of output shaft.
- Measure in at least two places.
- Calculate dimension T".
F = H - G





e. Measure distance "I" between end of output gear (adjusting spacer mating surface) and bearing inner race fitting surface.
f. Calculate dimension "T2".

"T2": Distance between adjusting spacer mating surface of output gear and output shaft
T2 = F - I

g. Select proper thickness of output shaft bearing adjusting spacer using image as a guide.





Output shaft bearing adjusting spacer: Refer to image.





2. Install bearing retainer on transmission case.





3. Place output shaft on bearing retainer.
4. Place output shaft bearing adjusting spacer selected in step 1-g on output shaft.
5. Press output gear bearing inner race on output gear.
6. Press output gear on output shaft.





7. Tighten output gear lock nut to specified torque.





8. Remove idler gear to measure output shaft preload.





9. Measure turning torque of output shaft.
- When measuring turning torque, turn output shaft in both directions several times to seat bearing rollers correctly.

Turning torque of output shaft: 0.25 - 0.88 Nm (2.5 - 9.0 kg-cm, 2.2 - 7.8 inch lbs.)





10. Install idler gear and tighten lock nut to specified torque.
11. After properly adjusting "turning" torque, clinch idler gear and output gear lock nuts as shown.





12. Install new gasket and side cover on transmission case.

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 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.





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.
- Forward clutch and bearings must be correctly installed for snap ring to 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.