Assembly (1)
Transmission Assembly Assembly (1)
1) Drive manual shaft oil seals into the transmission case until they are flush using suitable tool.
CAUTION:
- Apply ATF to manual shaft oil seals.
- Do not reuse manual shaft oil seals.
2) Install detent spring and spacer in transmission case and secure with the bolt.
3) Install manual shaft to transmission case.
4) Install parking rod to manual plate.
5) Install manual plate (with parking rod) to manual shaft.
6) Install retaining pin into the manual plate and manual shaft.
a) Align pinhole of the manual plate to pinhole of the manual shaft using suitable tool.
b) Tap the retaining pin into the manual plate using suitable tool.
CAUTION:
- Drive retaining pin to 2 ± 0.5 mm (0.08 ± 0.020 in) over the manual plate.
- Do not reuse retaining pin.
7) Install retaining pin into the transmission case and manual shaft.
a) Align pinhole of the transmission case to pinhole of the manual shaft using suitable tool.
b) Tap the retaining pin into the transmission case using suitable tool.
CAUTION:
- Drive retaining pin to 5 ± 1 mm (0.20 ± 0.04 in) over the transmission case.
- Do not reuse retaining pin.
8) Install O-rings to servo assembly.
CAUTION:
- Do not reuse O-rings.
- Apply petroleum jelly to O-rings.
9) Install return spring to servo assembly.
10) Install servo assembly in transmission case.
11) Install snap ring to transmission case using suitable tool.
12) Install D-rings in reverse brake piston.
CAUTION:
- Do not reuse D-rings.
- Apply ATF to D-rings.
13) Install reverse brake piston in transmission case.
14) Install needle bearing to drum support edge surface.
CAUTION:
Apply petroleum jelly to needle bearing.
15) Install seal rings to drum support.
CAUTION:
- Do not reuse seal rings.
- Apply petroleum jelly to seal rings.
16) Install spring retainer and return spring in transmission case.
17) Install snap ring in transmission case while compressing return spring using Tool.
CAUTION:
Securely assemble them using a flat-bladed screwdriver so that snap ring tension is slightly weak.
18) Install reverse brake drive plates driven plates and dish plates in transmission case.
CAUTION:
Take care with order of plates.
- QR25DE models
- Snap ring (1)
- Retaining plate (2)
- Drive plate (3)
- Driven plate (4)
- Dish plate (5)
- Drive plate/Driven plate:5/6
- VQ40DE models
- Snap ring (1)
- Retaining plate (2)
- Drive plate (3)
- Driven plate (4)
- Dish plate (5)
- Drive plate/Driven plate:6/6
19) Assemble N-spring.
20) Install reverse brake retaining plate in transmission case.
21) Install snap ring in transmission case.
22) Measure clearance (A) between retaining plate and snap ring. If not within specified clearance, select proper retaining plate.
[Location of Adjusting Shims, Needle Bearings, Thrust Washers and Snap Rings] Mechanical Specifications
23) Install needle bearing to transmission case.
CAUTION:
- Take care with the direction of needle bearing. Refer to Location of Adjusting Shims, Needle Bearings, Thrust Washers and Snap Rings.
- Apply petroleum jelly to needle bearing.
24) Install output speed sensor (1) to transmission case and tighten bolt to specified torque.
CAUTION:
- Do not subject sensor to impact by dropping or hitting it.
- Do not disassemble sensor.
- Do not allow metal filings or any foreign material to get on the sensor's front edge magnetic area.
- Do not place sensor in an area affected by magnetism.
25) Install new rear oil seal until it is flush into the rear extension case (2WD models) using Tool or adapter case (4WD models) using suitable tool.
CAUTION:
- Apply ATF to rear oil seal.
- Do not reuse rear oil seal.
26) Install return spring (1) to parking pawl (2).
27) Install parking pawl (with return spring) and pawl shaft to rear extension (2WD models) or adapter case (4WD models).
28) Install parking actuator support to rear extension (2WD models) or adapter case (4WD models).
29) Install needle bearing (1) to rear extension (2WD models) or adapter case (4WD models).
CAUTION:
Apply petroleum jelly to needle bearing.
30) Install seal rings to output shaft.
CAUTION:
- Do not reuse seal rings.
- Apply petroleum jelly to seal rings.
31) Install parking gear to output shaft.
32) Install output shaft in transmission case.
CAUTION:
Do not mistake front of shaft for rear because both sides look similar (thinner end is front side).
33) Install bearing race to output shaft.
34) Install rear extension assembly (2WD models) or adapter case assembly (4WD models) according to the following procedures.
a) 2WD models
i) Apply recommended sealant (Genuine Anaerobic Liquid Gasket or equivalent. Refer to [Recommended Chemical Products and Sealants] Recommended Chemical Products and Sealants.) to rear extension assembly as shown.
CAUTION:
Completely remove all moisture, oil, old sealant and any foreign material from the transmission case and rear extension assembly mating surfaces.
ii) Install rear extension assembly to transmission case.
CAUTION:
Insert the tip of parking rod between the parking pawl and the parking actuator support when assembling the rear extension assembly.
iii) Install the bracket (1), (2) and rear extension assembly bolts and tighten to the specified torque.
- Self sealing bolt (3)
- Bolt (A)
CAUTION:
Do not reuse self-sealing bolt.
b) 4WD models
i) Install gasket onto transmission case.
CAUTION:
- Completely remove all moisture, oil, old gasket and any foreign material from the transmission case and adapter case assembly mating surfaces.
- Do not reuse gasket.
ii) Install adapter case assembly to transmission case.
CAUTION:
Insert the tip of parking rod between the parking pawl and the parking actuator support when assembling the rear extension assembly.
iii) Tighten adapter case assembly to specified torque.
- 1:
- 2: Brackets
- 3: Self-sealing bolts
CAUTION:
Do not reuse self-sealing bolt (2).
35) Install direct clutch assembly in reverse brake.
CAUTION:
Make sure that drum support edge surface and direct clutch inner boss edge surface come to almost same place.
36) Install needle bearing in drum support.
CAUTION:
Apply petroleum jelly to needle bearing.
37) Install high and low reverse clutch assembly in direct clutch.
38) Align the drive plate using suitable tool.
39) Install high and low reverse clutch hub, mid sun gear assembly and rear sun gear assembly as a unit.
CAUTION:
Make sure that portion "A" of high and low reverse clutch drum protrudes approximately 2 mm (0.08 in) beyond portion "B" of rear sun gear.
40) Install needle bearing in rear carrier assembly.
CAUTION:
Apply petroleum jelly to needle bearing.
41) Install bearing race in rear carrier assembly.
CAUTION:
Apply petroleum jelly to bearing race.
42) Install rear carrier assembly in direct clutch drum.
43) Install needle bearing (rear side) to mid carrier assembly.
CAUTION:
Apply petroleum jelly to needle bearing.
44) Install needle bearing (front side) to mid carrier assembly.
CAUTION:
Apply petroleum jelly to needle bearing.
45) Install mid carrier assembly in rear carrier assembly.
46) Install front carrier assembly, input clutch assembly and rear internal gear as a unit.
47) Install seal rings in input clutch assembly.
CAUTION:
- Do not reuse seal rings.
- Apply petroleum jelly to seal rings.
48) Install band servo anchor end pin and lock nut in transmission case.
CAUTION:
Do not reuse band servo anchor end pin.
49) Install brake band in transmission case.
CAUTION:
Install it so that the identification to avoid incorrect installation faces the servo side.
50) Install front sun gear to front carrier assembly.
CAUTION:
Apply ATF to front sun gear bearing and 3rd one-way clutch end bearing.
51) Install needle bearing to front sun gear.
CAUTION:
Apply petroleum jelly to needle bearing.
52) Adjust brake band tilting using a clip so that brake band contacts front sun gear drum evenly.
53) Adjust brake band.
a) Loosen lock nut.
b) Tighten band servo anchor end pin to specified torque.
c) Back off band servo anchor end pin three turns.
d) Holding band servo anchor end pin, tighten lock nut to specified torque.
