AT Main Case
AT Main CaseREMOVAL
1. Remove the transmission assembly from vehicle.
2. Pull out the torque converter assembly.
3. Remove the transmission harness connector from stay.
4. Disconnect the air breather hose.
5. Remove the oil charge pipe.
6. Remove the ATF filter inlet and outlet pipes.
7. Remove the extension case and intermediate case.
8. Remove the center differential carrier.
9. Remove the reduction driven gear.
10. Separate the converter case and transmission case.
11. Remove the control valve body.
12. Remove the oil pump cover.
NOTE: The input clutch pack assembly and front sun gear assembly are also removed together.
13. Remove the needle bearing of the mid carrier assembly.
14. Remove the mid carrier assembly.
15. Remove the rear carrier assembly.
16. Remove the mid & rear sun gear assembly.
17. Remove the thrust needle bearing of high & low reverse clutch.
18. Remove the high & low reverse clutch assembly.
19. Remove the direct clutch assembly.
20. Remove the snap ring of reverse brake.
21. Remove the retaining plate.
22. Remove the leaf spring.
23. Take out the drive plate, driven plate and dish plate.
24. Remove the snap ring of the spring retainer of reverse brake.
ST1 18762AA000 COMPRESSOR SPECIAL TOOL
ST2 18765AA000 COMPRESSOR SUPPORT
ST3 18763AA000 COMPRESSOR SHAFT
25. Remove the spring retainer.
26. Remove the return spring.
27. Apply compressed air.
28. Remove the reverse brake piston.
INSTALLATION
1. Install the reverse brake piston.
NOTE: Apply ATF onto the piston sliding surface.
ST1 18762AA000 COMPRESSOR SPECIAL TOOL
ST2 18765AA000 COMPRESSOR SUPPORT
ST3 18763AA000 COMPRESSOR SHAFT
2. Install the return spring.
3. Install the spring retainer and snap ring.
ST1 18762AA000 COMPRESSOR SPECIAL TOOL
ST2 18765AA000 COMPRESSOR SUPPORT
ST3 1 8763AA000 COMPRESSOR SHAFT
4. Install the dish plate.
NOTE: When installing, make sure that the identification mark is facing the front side of transmission.
5. Install the drive plate and driven plate.
6. Install the leaf spring.
7. Install the retaining plate.
8. Install the snap ring of reverse brake.
9. Perform the clearance check of reverse brake.
1. Measure the clearance between retainer plate and snap ring using thickness gauge.
Standard value: 0.7 - 1.1 mm (0.028 - 0.043 inch)
2. If the clearance is out of specification, select a suitable retainer plate from following table and assemble it.
10. Install the direct clutch assembly.
11. Install the high & low reverse clutch assembly.
12. Install the thrust needle bearing of high & low.
13. Install the middle & rear sun gear assembly.
14. Install the rear carrier assembly.
15. Install the middle carrier assembly.
16. Install the thrust needle bearing of middle carrier assembly.
17. Measure the total end play, and select the bearing.
18. Install the impact clutch pack assembly to oil Pump cover.
19. Turn the transmission sideways.
20. Install the oil pump cover.
1. Apply ATF to the O-ring of input clutch shaft.
2. Install the oil pump cover to AT main case while supporting the input clutch shaft and oil pump housing by hand.
3. Make sure the rear end of drive pinion shaft is engaged to the spline of reduction driven gear.
4. Using a cloth, protect the input clutch shaft and rotate to engage the spline of input clutch and rear carrier using pliers.
NOTE: Work with pressing oil pump cover.
5. Combine the oil pump cover with transmission main case.
Tightening torque: 41 Nm (4.2 kgf-cm, 30.4 ft. lbs.)
21. Install the center differential carrier.
22. Install the reduction driven gear.
23. Install the extension case and intermediate case.
24. Install the control valve body.
25. Install the converter case assembly into transmission case assembly.
26. Install the air breather hose.
27. Install the ATF filter pipe.
28. Install the oil charge pipe with O-ring.
29. Install the torque converter assembly.
30. Install the transmission assembly into vehicle.
31. Perform the Clear Memory 2.
32. Perform the inspection with driving the vehicle et the end of repair work, and make sure there is no faulty as below;
^ Excessive shift shock
^ Oil leakage from transmission body and etc.
^ Occurrence of noise caused by interference etc.
NOTE: If excessive shift shock is felt, execute the advance operation of learning control.
DISASSEMBLY
INPUT CLUTCH PACK ASSY
1. Remove the front sun gear.
2. Remove the snap ring, and then remove the front carrier.
3. Remove the input clutch assembly from rear internal gear.
ASSEMBLY
INPUT CLUTCH PACK ASSY
1. Assemble the input clutch assembly to rear internal gear.
2. Install the front carrier, and then install the snap ring.
3. Install the front sun gear.
INSPECTION
FRONT, MIDDLE & REAR PLANETARY CARRIER ASSY
Inspect the followings:
^ Visually inspect the tooth surface of planetary gear, and replace with new one if damaged, broken or excessively worn.
^ Inspect the planetary carrier body for damage or brakeage.
INPUT CLUTCH
Check for damage of drive plate, driven plate and snap ring, and replace them as input clutch assembly if damaged.
HIGH & LOW REVERSE CLUTCH ASSEMBLY
Check the clearance of high & low reverse clutch.
Measure the clearance L between snap ring and retaining plate using thickness gauge. If the measured value is out of specification, replace them as high & low reverse clutch assembly.
Standard value: 1.8 - 2.2 mm (0.070 - 0.087 inch)
DIRECT CLUTCH ASSEMBLY
Check the clearance of direct clutch.
Measure the clearance L between snap ring and retaining plate using thickness gauge. If the measured value is out of specification, replace them as direct clutch assembly.
Standard value: 0.6 - 1.0 mm (0.024 - 0.039 inch)
REVERSE BRAKE
Check the following items:
^ Drive plate facing for wear and damage
^ Snap ring for wear, return spring for breakage, and spring retainer for deformation
^ Lip seal and D-ring for damage
^ Piston operation
ADJUSTMENT
1. Using the ST, measure the height A from AT main case mating surface to convex surface of oil pump cover.
ST 499575400 GAUGE
2. Using the ST, measure the depth B from the convex surface of oil pump cover to thrust bearing transferring surface.
ST 499575400 GAUGE
3. Calculate the measured value on step 1) and 2), and then set the calculated value as "C"
Calculation formula: C = A - B
4. Using the ST, measure the depth D from AT main case mating surface to thrust bearing transferring surface of front sun gear.
ST 499575400 GAUGE
5. Set the value as E which subtract the thickness of ST GAUGE from measured value on step 4).
Calculation formula: E (mm) = D - 15
[E (in) = D - 0.59]
6. Calculation formula:
Select a thrust bearing from the table to adjust clearance within 0.25 - 0.55 mm (0.0098 - 0.022 inch).
When clearances are 0.25 mm (0.0098 inch):
T(mm)=E-C+0.03
[T (in) = E - C + 0.0012]
When clearances are 0.55 mm (0.022 inch):
T (mm) = E - C - 0.27
[T (in) = E - C - 0.012]
T: Thrust bearing clearance
C: Distance from oil pump cover mating surface to rear end of oil pump cover
E: Depth from mating surface of AT main case to bearing surface of front sun gear
Example:
When the A is 39.50 mm (1.56 inch), B is going to be 16.20 mm (0.64 inch), so the C would be 23.30 mm (0.92 inch) by calculation.
When the D is 41.90 mm (1.65 inch), subtract the thickness of ST GAUGE from D, and then the value E would be 26.90 mm (1.06 inch).
Calculation when clearance is 0.25 mm (0.0098 inch)
T (mm) = 26.90 - 23.30 + 0.03 = 3.63
[T (in) = 1.059 - 0.917 + 0.0012 = 0.143]
Calculation formula when clearances are 0.55 mm (0.022 inch)
T (mm) = 26.90 - 23.30 - 0.27 = 3.33
[T (in) = 1.059 - 0.917 - 0.012 = 0.131]
According to the calculation, the value T would be 3.33 - 3.63 mm (0.131 - 0.143 inch), therefore select the thrust bearing with the thickness of 3.4 mm (0.134 inch) or 3.6 mm (0.142 inch) thrust bearing from the table.
NOTE: Calculation formula for "T" is applied when measuring using ST (499575400 GAUGE). In the calculation without using ST, insert the thickness of collar to calculate value E on step 5).