Connection of Each Section
CONNECTION OF EACH SECTION
1) Install the parking pawl, shaft and return spring.
2) Install inlet filter to transmission case.
3) Install transfer valve plate, valve body and duty solenoid C (transfer) to transmission case.
CAUTION:
- Be sure to install transfer seal lip to transfer control valve body.
- If transfer seal lip is damaged, replace seal with new one.
Tightening torque: 8±1 Nm (0.8± 0.1 kg-m, 5.8±0.7 ft. lbs.)
4) Connect connector to duty solenoid C (transfer).
5) Install the reduction drive gear assembly.
NOTE: Insert it fully into position until the bearing shoulder bottoms.
6) Using a plastic hammer, install reduction driven near assembly, and tighten drive pinion lock nut.
NOTE:
- Be sure to use a new lock nut and a washer.
- Set the select lever in the "P" range.
- After tightening, stake the lock nut securely.
Tightening torque: 98±5 Nm (10.0±0.5 kg-m, 72.3±3.6 ft. lbs.)
7) Measurement and adjustment of extension end play
1. Measure distance L from end of extension case and rear drive shaft with ST
ST 398643600 GAUGE
L = Measured value - 15 mm
2. Measure the distance "C" from the transmission case mating surface to the reduction drive gear end surface with ST1 and ST2.
l = Measured value - 50 mm
ST1 398643600 GAUGE
ST2 499577000 GAUGE
3. Calculation equation:
NOTE: Add 0.05 mm (0.0020 inch) and 0.20 mm (0.0079 inch) thick shims to area "T". Calculate formula 2 to determine "H". The calculated "H" refers to the shim thickness range. Select shims of suitable thicknesses within the calculated "H" range.
T= (L + G) - l - H
T: Shim clearance
L: Distance from end of extension case to end of rear drive shaft
G: Gasket thickness (0.45 mm, 0.0177 inch)
l : Height from end of transmission case to end of reduction drive gear
H: Thrust needle bearing thickness 0.05 - 0.25 mm (0.0020 - 0.0098 inch)
8) Installation of extension case and transmission case
1. Attach the selected thrust needle bearing to the end surface of reduction drive gear with vaseline.
CAUTION: Install thrust needle bearing in the correct direction. Refer to Location and Installing Direction of Thrust Needle Bearing. Location and Installing Direction of Thrust Needle Bearing
2. Install the extension case to the transmission case.
CAUTION: Be sure to use a new gasket.
3. Tighten bolts to secure the case.
Tightening torque: 25±2 Nm (2.5±0.2 kg-m, 18.1±1.4 ft. lbs.)
9) Install the vehicle speed sensor 1 (rear).
Tightening torque: 7±1 Nm (0.7±0.1 kg-m, 5.1±0.7 ft. lbs.)
7. EXTERNAL PARTS
1) Using ST, install ATF filter to transmission case. Calculate ATF filter torque specifications using the following formula.
T2 = L2/(L1 + L2) x T1
T1: 14±2 Nm (1.4±0.2 kg-m, 10.1±1.4 ft. lbs.)
[Required torque setting]
T2: Tightening torque
L1: ST length 0.078 m (3.07 inch)
L2: Torque wrench length
CAUTION: Align ST with torque wrench while tightening AFT filter.
ST 498545400 OIL FILTER WRENCH
2) Adjustment of inhibitor switch.
1. With the select lever set to "N" adjust the inhibitor switch so that the hole of range select lever is aligned with the inhibitor switch hole with ST.
NOTE: Ensure that gauge moves properly.
ST 499267300 STOPPER PIN
2. With hole aligned, tighten three bolts to secure the inhibitor switch.
Tightening torque: 3.4±0.5 Nm (0.35±0.05 kg-m, 2.5±0.4 ft. lbs.)
3) Install air breather hose.
4) Clip the following cords and harness.
5) Install the oil cooler outlet pipe.
CAUTION: Be sure to use a new aluminum washer.
Tightening torque: 34±3 Nm (3.5±0.3 kg-m, 25.3±2.2 ft. lbs.)
6) Install the oil cooler inlet pipe.
CAUTION: Be sure to use a new aluminum washer.
Tightening torque: 25±2 Nm (2.5±0.2 kg-m, 18.1±1.4 ft. lbs.)
7) Install the oil charge pipe.
CAUTION: Be careful not to damage the O-ring.
Tightening torque: 41±3 Nm (4.2±0.3 kg-m, 30.4±2.2 ft. lbs.)
8) Install the pitching stopper bracket.
Tightening torque: 41±3 Nm (4.2±0.3 kg-m, 30.4±2.2 ft. lbs.)
9) Tighten the drain plugs.
Tightening torque:
Diff: 44±3 Nm (4.5±0.3 kg-m, 32.5±2.2 ft. lbs.)
ATF: 25±2 Nm (2.5±0.2 kg-m, 18.1±1.4 ft. lbs.)
10) Insert the input shaft while turning lightly by hand.
CAUTION: Be careful not to damage the bushing.
Normal protrusion A: 50 - 55 mm (1.97 - 2.17 inch)
11) Install the torque converter clutch assembly.
1. Install the oil pump shaft to the torque converter clutch.
NOTE: Make sure the clip fits securely in its groove.
2. Holding the torque converter clutch assembly by hand, carefully install it to the torque converter clutch case. Be careful not to damage the bushing. Also avoid undue contact between the oil pump shaft bushing and stator shaft portion of the oil pump cover.
3. Rotate the shaft lightly by hand to engage the splines securely.
Dimension A: 2.7 - 2.9 mm (0. 106 - 0.114 inch)
12) Fill ATF and differential gear oil.
NOTE: After filling oil, insert the oil level gauge into the oil inlet.
Differential gear oil capacity: 1.1 - 1.3 l (1.2 - 1.4 US qt, 1.0 - 1.1 Imp qt)
Automatic transmission fluid capacity: 9.3 - 9.6 f (9.8 - 10. 1 US qt, 8.2 - 8.4 Imp qt)
Recommended fluid: Dexron III or Dexron III type automatic transmission