Part 5

Transmission Disassemble

Disassembly




1. Remove the clutch drum oil seal rings.




2. Remove the bolts (1-11) and stator shaft. Keep the gears in assembled order.




3. Remove the front oil pump drive gear (1).




4. Remove the front oil pump driven gear (1).




5. Using a screwdriver, pry out the O-ring.




6. Mount the oil pump in a soft jaw vise.
7. Using a suitable puller (1), tap out the oil seal from the oil pump body.




8. Turn the drive gear with two screwdrivers and make sure it rotates smoothly.




9. Push the driven gear to one side of the body. Using a feeler gage, measure the clearance.

* Standard body clearance - 0.10 to 0.17 mm (0.0039 to 0.0067 in)
* Maximum body clearance - 0.17 mm (0.0067 in)

10. If the body clearance is greater than the maximum, replace the oil pump body sub-assembly.




11. Measure the tip clearance between the driven gear teeth and drive gear teeth.

* Standard tip clearance - 0.07 to 0.15 mm (0.0028 to 0.0059 in)
* Maximum tip clearance - 0.15 mm (0.0059 in)

12. Using a straightedge and feeler gauge, measure the side clearance of both gears.

* Maximum side clearance -0.05 mm (0.002 in.)
* Standard side clearance - 0.02 to 0.05 mm (0.0008 to 0.002 in)




13. Inspect front oil pump and gear body subassembly.
14. Using a caliper gauge, measure the inside diameter of the oil pump body bushing.

* Standard inside diameter - 38.113 to 38.138 mm (1.5005 to 1.5014 in)
* Maximum inside diameter - 38.188 mm (1.5034 in)

15. If the inside diameter is grater than maximum, replace the oil pump body sub-assembly.




16. Inspect the stator shaft assembly.
17. Using a caliper gauge, measure the inside diameter of the stator shaft bushing.

* Standard inside diameter - 21.500 to 21.526 mm (0.8464 to 0.8474 in)
* Maximum inside diameter - 21.57 mm (0.8492 in)

18. If the indicator diameter is greater than the maximum, replace the stator shaft.




19. Place the matchmarks (1) on the ring gear and differential case.




20. Remove the bolts.




21. Using a plastic-faced hammer, tap on the ring gear to remove it from the case.




22. Using a suitable puller (3), tap out the front differential case front tapered roller bearing from the differential case.




23. Using a suitable puller (1), remove the front differential case front tapered roller bearing outer race.




24. Using a suitable puller (1), remove the front differential case rear tapered roller bearing from the differential case.




25. Using a suitable puller (1), tap out the front differential case front tapered roller bearing outer race.





Note: Before removing the straight pin, unstake it with a pin punch.

26. Using a pin punch and hammer, tap in the straight pin.




27. Remove the front differential pinion shaft from the differential case.




28. Remove the front differential pinions, pinion thrust washers, front differential side gears and side gear thrust washers from the differential case.




29. Using a suitable driver (1) and hammer, tap out the oil seal.




30. Using a suitable tool (1, 2) and hammer, tap out the oil seal.