Part 2 of 3

4. Remove the differential case assembly.

CAUTION:
- Remove the seal pipe if it is attached. (Reusing is not allowed.)
- Be careful not to damage the retainer mounting hole of the torque converter clutch case and the speedometer gears.






5. Remove the snap ring. Then remove the speedometer driven gear.





6. Tap out the speedometer shaft to the outside of the case, and remove the oil seal.

5. Extension Section





1. Take out the transfer clutch by lightly tapping the end of the rear drive shaft.

CAUTION: Be careful not to damage the oil seal in the extension.





2. Remove duty solenoid C, transfer valve body and the transfer pipe.

CAUTION:
- Take out the inlet filter.
- Do not damage the O-ring.
- Be careful not to bend the pipe.





3. Take out the roller bearing with ST.
ST 398527700 PULLER

C: ASSEMBLY OF OVERALL TRANSMISSION
1. 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 ST, and set the oil seal. Then force-fit the shaft to the torque converter clutch case.
ST 499827000 PRESS





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





4. Force-fit the oil seal to the torque converter clutch case with ST.
ST 398437700 DRIFT






5. 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).
6. 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:
Approx. 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.






7. Wrap vinyl tape around the splined portion of the axle shaft.
8. 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.






9. Using the ST, screw in the retainer until light contact is felt.
ST 499787000 WRENCH ASSY

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






10. Hypoid gear backlash adjustment and tooth contact check
1) 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.






2) Tighten four bolts to secure the roller bearing.

Tightening torque: 39 ± 3 Nm (28.9 ± 2.2 ft. lbs.)






3) 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.






4) Rotate the drive pinion several times with ST1 and ST2.
ST1 498937100 HOLDER
ST2 499787100 WRENCH





5) 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.





6) After the "zero" state is established, back off the LH retainer 3 teeth 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 teeth 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 in).






7) Turn the drive pinion several rotations with ST1 and check to see if the backlash is within the standard value with ST2, ST3 and ST4.
ST1 499787100 WRENCH
ST2 498247001 MAGNET BASE
ST3 498247100 DIAL GAUGE
ST4 499757800 ADAPTER WRENCH

Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)

NOTE: After confirming that the backlash is correct, check the tooth contact.






8) 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.





9) If tooth contact is correct, mark the retainer position and loosen it. After fitting the 0-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.)






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

CAUTION: Be sure to use a new seal pipe.





12. Install two oil seals to the oil seal retainer with ST.
ST 499247300 INSTALLER

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






13. 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.





14. 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.)





15. 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.





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

CAUTION: Be careful not to lose the rubber seal.

2. Transmission Case Section





1. Press-fit the roller bearing to the transmission case with ST.
ST 398487700 DRIFT





2. Using a plastic hammer, force-fit the oil seal.





3. Install the manual plate and shaft, and secure with a spring pin.

CAUTION: Be careful not to damage the oil seal lip.

NOTE: After installation, make sure of smooth movement.






4. Assemble the manual lever and parking rod to the inside shaft, and secure with a nut.

Tightening torque: 47 ± 2 Nm (34.7 ± 1.4 ft. lbs.)





5. Install inhibitor switch.
1) Install the inhibitor switch to the transmission case. Fit the projecting portion of the switch in the recessed portion of the case, and tighten three bolts temporarily.
2) Insert the range select lever into the shaft, and tighten the nut.

Tightening torque: 47 ± 5 Nm (34.7 ± 3.6 inch lbs.)





6. Install the detention spring.

NOTE: Position the spring so that its center is aligned with the center of the manual plate.

Tightening torque: 6 ± 1 Nm (4.3 ± 0.7 ft.lbs.)





7. Install the lathe cut seal rings to the I.D./O.D. of the low and reverse piston. Then install the piston into the case with a press, ST1 and ST2.
STI 398673600 COMPRESSOR
ST2 498627000 SEAT

CAUTION:
- Be careful not to tilt the piston when installing.
- Be careful not to damage the lip seal.





8. Install the one-way clutch inner race.
1) Using a press and ST1, install the needle bearing to the inner race.
ST1 398497701 INSTALLER

NOTE: Use the following ST when removing.

ST 398527700 PULLER ASSY





2) Install four seal rings and thrust washer.

NOTE: Apply vaseline to the groove of the inner race and to the seal ring after installation, so that the seal ring will not expand.





3) Place the spring retainer on the inner race. Install the spring to the recessed portion of the piston. Then tighten eight socket head bolts from the rear side of the transmission case.

Tightening torque: 25 ± 2 Nm (18.1 ± 1.4 ft. lbs.)

CAUTION: Be sure to tighten evenly.






9. Install the band servo sub assembly.
10. Press the O.D. servo retainer into position with ST1 and ST2, and secure with a snap ring.
ST1 498677010 COMPRESSOR
ST2 399703600 PULLER ASSY

CAUTION: Perform the following operations with the transmission case set vertically on wooden blocks.

11. Measure the drive plates thickness of the low & reverse brake.

Standard value: 1.8 mm (0.071 inch)
Allowable limit: 1.6 mm (0.063 inch)

12. Installation of the low & reverse brake:





1) Install dish plate, driven plates, drive plates, and a retaining plate, and secure with a snap ring.

NOTE: Pay attention to the orientation of the dish plate.

1): Snap ring
2): Retaining plate
3): Transmission case
4): Lathe cut seal ring
5): Dish plate
6): Piston
7): Bolt
8): Lathe cut seal ring
9): Clutch spring retainer
10): Forward clutch drum
11): Drive plate
12): Driven plate






2) Apply compressed air intermittently to check for operation.








3) Check the clearance. (Selection of retaining plate)

NOTE: Before measuring clearance, place the same thickness of shim on both sides to prevent retaining plate from tilting.

Standard value: 0.7 - 1.0 mm (0.028 - 0.039 in)
Allowable limit: 2.0 mm (0.079 in)





13. Install the forward clutch drum.
1) Install carefully while rotating the forward drum slowly paying special attention not to damage the seal ring.
2) Installation is complete when the forward drum recedes 2.5 mm (0.098 in) from the inner race surface.





14. Assemble the overrunning clutch hub.

CAUTION: Install thrust needle bearing in the correct direction.

NOTE:
- Join the thrust needle bearing and thrust washer with vaseline, and then install them together.
- Make sure that the splines are engaged correctly.





15. Install the one-way clutch outer race.

NOTE: Make sure the forward clutch splines are engaged correctly.






16. Assemble the rear internal gear.
1) Join the thrust needle bearing and thrust washer to the internal gear with vaseline, and install the internal gear while rotating it.
2) Securely engage the bearing with the dog of the overrunning clutch hub.

CAUTION: Install thrust needle bearing in the correct direction.

NOTE: Installation is complete when the snap ring top surface of the forward clutch drum recedes approximately 3.5 mm (0. 138 i n).






17. Install the rear planetary carrier.
Attach the thrust needle bearing to the inside of the carrier with vaseline. Then install the carrier while rotating slowly.

CAUTION: Install thrust needle bearing in the correct direction.






18. Install the rear sun gear.

NOTE: Install the gear with the oil groove facing up.






19. Install the front planetary carrier.
Attach the thrust needle bearings to both sides of the carrier with vaseline. Install the carrier carefully, while aligning with the splines of the forward clutch drum, and while rotating the pinion.

CAUTION: Install thrust needle bearing in the correct direction.





20. Install the front sun gear.
Attach the thrust needle bearing to the gear, and install the gear while turning slowly.

CAUTION: Install thrust needle bearing in the correct direction.





21. Install the high clutch hub.
Attach the thrust needle bearing to the hub with vaseline and install the hub. by correctly engaging the splines of the front planetary carrier.

CAUTION: Install thrust needle bearing in the correct direction.





22. Install the high clutch assembly.

NOTE: Correctly engage the high clutch hub and clutch splines.