Torque Converter Clutch Case Section

1. Check the appearance of each component and clean.

CAUTION: Make sure each part is free of harmful cuts, damage and other faults.





2. Install the washer and snap ring to the speedometer shaft with Special Tool (ST), and set the oil seal. Then force-fit the shaft to the torque converter clutch case.
ST 499827000 Press or equivalent.
3. Install vehicle speed sensor 2.
Tightening Torque: 5.9 +/-1.5 Nm (52 +/-13 inch lbs.).

CAUTION: Use new vehicle speed sensor 2, if it has been removed.





4. Install the speedometer driven gear to the speedometer shaft. and secure with a snap ring.





5. Force-fit the oil seal to the torque converter clutch case with ST.
ST 398437700 Drift or equivalent.





6. Install the differential assembly to the case, paying special attention not to damage the speedometer gears (drive and driven) and the inside of the case (particularly, the differential side retainer contact surface).
7. Install the circlip to the axle shaft, insert the shaft into the differential assembly, and tap it into position with a plastic hammer.
Thrust Play: Approximately 0.3 - 0.5 mm (0.012 - 0.020 inch).

CAUTION:
- If no play is felt, check whether the shaft is fully inserted. If shaft insertion is correct, replace the axle shaft.
- Be sure to use a new circlip.





8. Wrap vinyl tape around the spliced portion of the axle shaft.
9. Install the oil seal and outer race (taper roller bearing) to the differential side retainer. Then screw in the retainer and the O-ring after coating the threads with oil.

CAUTION:
- Pay attention not to damage the oil seal lips.
- Do not confuse the RH and LH oil seals.
- Keep the O-ring removed from the retainer.





10. Using the ST, screw in the retainer until light contact is felt.
ST 499787000 Wrench Assy or equivalent.

NOTE: Screw in the RH side slightly deeper than the LH side.





11. Hypoid gear backlash adjustment and tooth contact check
a. Assemble the drive pinion assembly to the oil pump housing.

CAUTION:
- Be careful not to bend the shims.
- Be careful not to force the pinion against the housing bore.





b. Tighten four bolts to secure the roller bearing.
Tightening Torque: 39 +/-3 Nm (28.9 +/-2.2 ft. lbs.).





c. Install the oil pump housing assembly to the torque converter clutch case, and secure evenly by tightening four bolts.
Tightening Torque: 41 +/-3 Nm (30.4 +/-2.2 ft. lbs.).

CAUTION:
- Thoroughly remove the liquid gasket from the case mating surface beforehand.
- Use an old gasket or an aluminum washer so as not to damage the mating surface of the housing.





d. Rotate the drive pinion several times with ST1 and ST2.
ST1 498937100 Holder or equivalent.
ST2 499787100 Wrench or equivalent.





e. Tighten the LH retainer until contact is felt while rotating the shaft. Then loosen the RH retainer. Keep tightening the LH retainer and loosening the RH retainer until the pinion shaft can no longer be turned. This is the "zero" state.





f. After the "zero" state is established, back off the LH retainer 3 notches and secure it with the lock plate. Then back off the RH retainer and retighten until it stops. Repeat this procedure several times. Tighten the RH retainer 1-3/4 notches further. This sets the preload. Finally, secure the retainer with its lock plate.

NOTE: Turning the retainer by one tooth changes the backlash about 0.05 mm (0.0020 inch).





g. Turn the drive pinion several rotations with ST1 and check to see if the backlash is within the standard value with ST2 and ST3.
ST1 499787100 Wrench or equivalent.
ST2 498247001 Magnet Base or equivalent.
ST3 498247100 Dial Gauge or equivalent.
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch).
After confirming that the backlash is correct, check the tooth contact.





h. Apply red lead evenly to the surfaces of three or four teeth of the crown gear. Rotate the drive pinion in the forward and reverse directions several times. Then remove the oil pump housing, and check the tooth contact pattern.
If tooth contact is improper, readjust the backlash or shim thickness.





i. If tooth contact is correct, mark the retainer position and loosen it. After fitting the O-ring, screw in the retainer to the marked position. Then tighten the lock plate to the specified torque.
Tightening Torque: 25 +/-2 Nm (18.1 +/-1.4 ft. lbs.).





12. Install the seal pipe to the torque converter clutch case.

CAUTION: Be sure to use a new seal pipe.





13. Install two oil seals to the oil seal retainer with ST.
ST 499247300 Installer or equivalent.

CAUTION:
- Always discard old oil seals, and install new ones.
- Pay attention to the orientation of the oil seals.





14. Attach the O-ring to the oil seal retainer with Vaseline. Install the seal to the oil pump housing bore.

CAUTION: Always discard old O-rings and install new ones.





15. Install the oil seal retainer taking care not to damage the oil seal lips. Then secure with three bolts.

NOTE: Make sure the O-ring is fitted correctly in position.

Tightening Torque: 7 +/-1 Nm (5.1 +/-0.7 ft. lbs.).





16. Apply Vaseline to the groove on the oil pump cover, and install two (R) seal rings and two (H) seal rings.

NOTE:
- Fit the seal ring after compressing, and rub Vaseline into the seal ring to avoid expansion.
- The "R" seal ring has a large diameter, while "H" has small diameter.





17. Install the rubber seal to the torque converter clutch case.

CAUTION: Be careful not to lose the rubber seal.