Assembly (1)

ASSEMBLY


Assembly (1)






1. As shown in the figure, use a drift [22 mm (0.87 in) dia. commercial service tool] to drive manual shaft oil seals into the transmission case until it is flush.

CAUTION:
- Never reuse manual shaft oil seals.
- Apply ATF to manual shaft oil seals.





2. Install detent spring and spacer in transmission case. Tighten detent spring and spacer bolts to the specified torque. Component.





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. Fit pinhole of the manual plate to pinhole of the manual shaft with a pin punch.
b. Use a hammer to tap the retaining pin into the manual plate.

CAUTION:
- Never reuse retaining pin.
- Drive retaining pin to 2�0.5 mm (0.08�0.020 in) over the manual plate.





7. Install retaining pin into the transmission case and manual shaft.
a. Fit pinhole of the transmission case to pinhole of the manual shaft with a pin punch.
b. Use a hammer to tap the retaining pin into the transmission case.

CAUTION:
- Never reuse retaining pin.
- Drive retaining pin to 5�1 mm (0.20�0.04 in) over the transmission case.





8. Install O-rings to servo assembly.

CAUTION:
- Never reuse O-rings.
- Apply petroleum jelly to O-rings.





9. Install return spring to servo assembly.





10. Install servo assembly in transmission case.





11. Using a pair of snap ring pliers, install snap ring to transmission case.





12. Install D-rings in reverse brake piston.

CAUTION:
- Never 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:
- Never reuse seal rings.
- Apply petroleum jelly to seal rings.





16. Install spring retainer and return spring in transmission case.





17. Set the SST on spring retainer and install snap ring (fixing spring retainer) in transmission case while compressing return spring.

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.

1: Snap ring
2: Retaining plate
3: Drive plate
4: Driven plate
5: Dish plate
6/6: Drive plate/Driven plate





19. Assemble N-spring.
20. Install reverse brake retaining plate in transmission case.





21. Install snap ring in transmission case.





22. Measure clearance between retaining plate and snap ring. If not within specified clearance, select proper retaining plate.

Specified clearance A
Standard: 0.7 - 1.1 mm (0.028 - 0.043 in)
Retaining plate
Refer to AT-334, "Reverse Brake". Reverse Brake





23. Install needle bearing to transmission case.

CAUTION:
- Take care with the direction of needle bearing. .
- Apply petroleum jelly to needle bearing.





24. Install output speed sensor (1) to transmission case. Tighten bolt ( ) to the specified torque. Component.

CAUTION:
- Never subject it to impact by dropping or hitting it.
- Never disassemble.
- Never allow metal filings, etc., to get on the sensor's front edge magnetic area.
- Never place in an area affected by magnetism.
25. Assemble each part according to the following procedures.
a. 2WD models i. Install return spring (1) to parking pawl (2).





ii. Install parking pawl (with return spring) (1) and pawl shaft (2) to output shaft & companion flange complement.





iii. Install parking actuator support (1) from output shaft & companion flange complement.





b. AWD models i. As shown in the figure, use the drift [64 mm (2.52 in) dia. commercial service tool] (A) to drive rear oil seal into the adapter case until it is flush.

CAUTION:





- Apply ATF to rear oil seal.
- Never reuse rear oil seal.





ii. Install return spring (1) to parking pawl (2).





iii. Install parking pawl (with return spring) and pawl shaft to adapter case.





iv. Install parking actuator support from adapter case.





v. Install needle bearing (1) to adapter case.

CAUTION:
- Take care with the direction of needle bearing. .
- Apply petroleum jelly to needle bearing. Refer to GI section to make sure icons (symbol marks) in the figure. Key to Symbols.
26. Assemble output shaft & companion flange complement (2WD) or adapter case assembly (AWD) according to the following procedures.
a. 2WD models i. Install seal rings to intermediate shaft.

CAUTION:





- Never reuse seal rings.
- Apply petroleum jelly to seal rings.





ii. Install intermediate shaft in transmission case.

CAUTION:
Be careful not to mistake front for rear because both sides looks similar. (Thinner end is front side.)





iii. Apply recommended sealant (Genuine Anaerobic Liquid Gasket or equivalent. Fluid Type Specifications.) to output shaft & companion flange complement as shown in the figure.

CAUTION:
Completely remove all moisture, oil and old sealant, etc. from the transmission case and output shaft & companion flange complement mounting surfaces.





iv. Install output shaft & companion flange complement in transmission case.

CAUTION:
Insert the tip of parking rod between the parking pawl and the parking actuator support when assembling the output shaft & companion flange complement.





v. Tighten output shaft & companion flange complement bolts (1) to the specified torque. Component.

Black arrow: Bolt

CAUTION:
Never reuse self-sealing bolts (2). Refer to GI section to make sure icons (symbol marks) in the figure. Key to Symbols.
b. AWD models





i. Install seal rings to output shaft.

CAUTION:
- Never reuse seal rings.
- Apply petroleum jelly to seal rings.





ii. Install parking gear to output shaft.





iii. Install output shaft in transmission case.

CAUTION:
Be careful not to mistake front for rear because both sides looks similar. (Thinner end is front side.)





iv. Install bearing race to output shaft.





v. Install gasket onto transmission case.

CAUTION:
- Completely remove all moisture, oil and old gasket, etc. from the transmission case and adapter case assembly mounting surfaces.
- Never reuse gasket.





vi. 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 adapter case assembly.





vii. Tighten adapter case assembly bolts (1) to the specified torque.
[With bracket (2).] Component.

Black arrow: Bolt

CAUTION:
Never reuse self-sealing bolts (3). Refer to GI section to make sure icons (symbol marks) in the figure. Key to Symbols.





27. Install needle bearing in drum support.

CAUTION:
- Take care with the direction of needle bearing. .
- Apply petroleum jelly to needle bearing.





28. 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.





29. Install high and low reverse clutch assembly in direct clutch.





30. Using a flat-bladed screwdriver, align the drive plate.





31. 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.





32. Install needle bearing in rear carrier assembly.

CAUTION:
- Take care with the direction of needle bearing. .
- Apply petroleum jelly to needle bearing.





33. Install bearing race in rear carrier assembly.

CAUTION:
Apply petroleum jelly to bearing race.





34. Install rear carrier assembly in direct clutch drum.





35. Install needle bearing (rear side) to mid carrier assembly.

CAUTION:
- Take care with the direction of needle bearing. .
- Apply petroleum jelly to needle bearing.





36. Install needle bearing (front side) to mid carrier assembly.

CAUTION:
- Take care with the direction of needle bearing. .
- Apply petroleum jelly to needle bearing.





37. Install mid carrier assembly in rear carrier assembly.





38. Install front carrier assembly, input clutch assembly and rear internal gear as a unit.





39. Install seal rings in input clutch assembly.

CAUTION:
- Never reuse seal rings.
- Apply petroleum jelly to seal rings.





40. Install band servo anchor end pin and lock nut in transmission case.

CAUTION:
Never reuse band servo anchor end pin.





41. Install brake band in transmission case.

CAUTION:
Assemble it so that identification to avoid incorrect installation faces servo side.





42. Install front sun gear to front carrier assembly.

CAUTION:
Apply ATF to front sun gear bearing and 3rd one-way clutch end bearing.





43. Install needle bearing to front sun gear.

CAUTION:
Apply petroleum jelly to needle bearing.





44. Adjust brake band tilting using a clip so that brake band contacts front sun gear drum evenly.





45. Adjust brake band.
a. Loosen lock nut.
b. Tighten band servo anchor end pin to specified torque.

Torque: 5.0 Nm (0.51 kg-m, 44 in-lb)

c. Back of band servo anchor end pin three turns.
d. Holding band servo anchor end pin, tighten lock nut to the specified torque. Component.