Assemble Unit (Planetary Gearbox)

Assemble





- Install O-ring into planet carrier.

NOTE: After replacing planet carrier, adjust. Adjustments





- Install axial needle bearing with washers in input gear.
1 - Input gear, installed in transmission housing.
2 - Axial needle bearing washer, install smooth side into input gear.
3 - Axial needle bearing
4 - Axial needle bearing washer
5 - Planet carrier, install with sea] fitted





- Place washer and axial needle bearing on small sun gear in planet carrier.
- Centralize washer and axial needle bearing in small sun gear.
- Install inner and outer -B1- plates.
- Install pressure plate with flat side facing plates.
Thickness of pressure plate varies according to number of plates, refer to Code Letters, Application, Ratios, Equipment. Application and ID





- Install dished washer with convex side facing toward free wheel.

NOTE: When replacing
^ transmission housing
^ Free wheel
^ Piston for reverse gear brake -B1-
^ Plates
Adjust -B1-. Adjustments





- Preload free wheel rollers with 3267 and install free wheel.





- Install circlip for free wheel -b- and circlip for supporting tube -a-.
- Install circlip gaps over free wheel retaining wedge -arrow-.
- Install Transmission Vehicle Speed Sensor -G38- refer to Index of Electrical/Electronic Component Repairs. Service and Repair
- Perform check measurement of -B1-. Adjustments





- Install components into transmission housing beginning with large sun wheel down to small input shaft.
1 - Large sun wheel
2 - Needle bearing washer (collar faces large sun wheel)
3 - Axial needle bearing
4 - Large input shaft
5 - Axial needle bearing
6 - Needle bearing
7 - Small input shaft





- Install small drive shaft bolt -1- with washer -2- and shim -3-.
Tighten to: 30 Nm (22 ft lb)

NOTE:
^ Insert shim -3- onto small drive shaft shoulder -arrow-.
^ Determining shim thickness refer to adjusting planet carrier. Adjustments

- Perform planet carrier check measurement. Adjustments





- Install axial needle bearing with washer on 4th gear clutch -K3-.
1 - Axial needle bearing with washer
2 - 4th gear clutch -K3-
- Moisten axial needle bearing washer with ATF so that bearing, when installed, sticks to -K3-.
- Install bearing washer on -K3-.





- Install 4th gear clutch -K3-.
- Install seal -1- in groove -arrow,

NOTE: Make sure the piston rings seat correctly.





- Install 1st to 3rd gear clutch -K1-.





- Install shims -arrow- in -K1-

NOTE:
^ Remeasure shim when replacing -K1-, -K2- or ATF pump refer to adjusting clutch play between -K1- and -K2-. Adjustments
^ 1 or 2 shims can be installed.

- Install reverse gear clutch -K2-.





- Install supporting tube for -B2- plate set -arrow- so that supporting tube groove engages in free wheel wedge.





- Install -B2- plates as follows:
First install 3 mm thick outer plate
Install three spring caps in outer plate
Install compression springs -arrows
Install all but last outer plate
- Before installing last (measured) outer plate, install three spring caps onto compression springs.
- Replace corrugated washer

NOTE: When replacing
^ Supporting tube
^ ATF pump
^ Plates
then adjust 2nd and 4th gear brakes -B2-. Adjustments

- Replace ATF pump seal.
- Install O-ring on ATF pump..





- Install ATF pump.
- Tighten bolts evenly in a crosswise pattern.

NOTE:
^ Make sure that the O-ring is not damaged.
^ Tighten to: 8 Nm (71 inch lb) plus an additional 90° (1/4 turn) further.
^ Additional 1/4 turn can be done in stages.

- Check measurement of clutch play. Adjustments
- Install sealing plugs, valve body and oil pan refer to Replacement. Service and Repair
- Install cover with gasket and spacer bushings.





- Install ATF overflow pipe -1- and level plug -2-.