Part 2
TRANSMISSION ASSEMBLY Continued
Assembly
25. Install needle bearing (1) to rear extension (2WD) or adapter case (AWD).
CAUTION:
Check the direction of needle bearing. Oil Channel Location Of Needle Bearings And Bearing Races, "Location of Needle Bearings and Bearing Races".
26. Install rear extension assembly (2WD) or adapter case assembly (AWD) according to the following procedures.
a. 2WD
i. Install seal rings (1) to output shaft.
ii. Install parking gear (1) to output shaft (2).
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. Apply recommended sealant to rear extension assembly as shown in the figure.
Use Anaerobic Liquid Gasket or an equivalent. Recommended Chemical Products And Sealants, "Recommended Chemical Products and Sealants".
Sealant starting point and endpoint (A) : Start and finish point shall be in the center of two bolts.
Overlap width of sealant starting point and endpoint (B) : 3 - 5 mm (0.12 - 0.20 in)
Sealant width (C) : 1.0 - 2.0 mm (0.04 - 0.08 in)
Sealant height (C) : 0.4 - 1.0 mm (0.016 - 0.04 in)
CAUTION:
Completely remove all moisture, oil and old sealant, etc. from the transmission case and rear extension assembly mounting surfaces.
vi. 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.
vii. Tighten rear extension assembly bolts to the specified torque.
A : Bolt
B : Self-sealing bolt
b. AWD
i. Install seal rings (1) to output shaft.
ii. Install parking gear (1) to output shaft (2).
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 to the specified torque.
1 : Bracket
A : Bolt
B : Self-sealing bolt
27. Install needle bearing in drum support.
CAUTION:
Check the direction of needle bearing. Oil Channel Location Of Needle Bearings And Bearing Races, "Location of Needle Bearings and Bearing Races".
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. Align the drive plate using a flat-bladed screwdriver.
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:
Check the direction of needle bearing. Oil Channel Location Of Needle Bearings And Bearing Races, "Location of Needle Bearings and Bearing Races".
33. Install bearing race in rear carrier assembly.
CAUTION:
Check the direction of needle bearing. Oil Channel Location Of Needle Bearings And Bearing Races, "Location of Needle Bearings and Bearing Races".
34. Install rear carrier assembly in direct clutch drum.
35. Install needle bearing (rear side) to mid carrier assembly.
CAUTION:
Check the direction of needle bearing. Oil Channel Location Of Needle Bearings And Bearing Races, "Location of Needle Bearings and Bearing Races".
36. Install needle bearing (front side) to mid carrier assembly.
CAUTION:
Check the direction of needle bearing. Oil Channel Location Of Needle Bearings And Bearing Races, "Location of Needle Bearings and Bearing Races".
37. Install mid carrier assembly in rear carrier assembly.
38. Install seal rings (1) to input clutch assembly.
39. Install needle bearing (1) to front carrier assembly.
CAUTION:
Check the direction of needle bearing. Oil Channel Location Of Needle Bearings And Bearing Races, "Location of Needle Bearings and Bearing Races".
40. Install input clutch assembly (with front carrier assembly and rear internal gear) (1) to transmission case.
CAUTION:
Check that the needle bearing (2) is securely positioned. If the needle bearing position is misaligned, adjust it to the specified position.
41. Install 1st one-way clutch (1) to front brake hub (with under drive carrier) (2).
42. Check operation of 1st one-way clutch.
a. Hold 1st one-way clutch.
b. Check front brake hub for correct locking and unlocking directions.
Black Arrow: Unlocked
White Arrow: Locked
CAUTION:
If not shown in figure, check installation direction of 1st one-way clutch.
43. Install under drive carrier (with 1st one-way clutch) (1) to transmission case.
44. Install snap ring (1) to transmission case.
CAUTION:
Be careful not to damage snap ring.
45. Install front brake retaining plate (thin) (1), front brake drive plates (2), front brake driven plate (3), and front brake retaining plate (thick) (4) to transmission case.
Arrow :Front
CAUTION:
Check order of plates.
46. Install needle bearing (1) to under drive carrier assembly.
CAUTION:
Check the direction of needle bearing. Oil Channel Location Of Needle Bearings And Bearing Races, "Location of Needle Bearings and Bearing Races".
47. Install under drive sun gear (1) to under drive carrier assembly.
48. Adjustment of total end play "T".
- Measure clearance between bearing race (1) and oil pump cover (2).
- Select proper thickness of bearing race so that end play is within specifications.
a. Measure dimensions "K" and "L", and calculate dimension "J".
1 : Transmission case
2 : Under drive sun gear
A : Straightedge
"J" : Distance between the oil pump fitting surface of transmission case and the needle bearing mating surface of under drive sun gear.
J = K - L
i. Measure dimension "K" between the converter housing fitting surface of transmission case and the needle bearing mating surface of under drive sun gear.
CAUTION:
Never change the straight edge installation position before the completion of "L" measurement.
ii. Measure dimension "L" between the converter housing fitting surface of transmission case and the oil pump fitting surface of transmission case.
iii. Measure dimension "K" and "L" in at least three places, and take the average.
iv. Calculate dimension "J".
J = K - L
b. Measure dimensions "M1" and "M2", and calculate dimension "M".
1 : Bearing race
2 : Needle bearing
3 : Oil pump assembly
A : Straightedge
"M" : Distance between the transmission case fitting surface of oil pump and the needle bearing on oil pump.
M = M1- M2
i. Place bearing race (1) and needle bearing (2) on oil pump assembly (3).
ii. Measure dimension "M1" between the transmission case fitting surface of oil pump and the end of oil pump.
1 : Bearing race
2 : Needle bearing
3 : Oil pump assembly
A : Straightedge
CAUTION:
Measure dimension "M1" in at least three places, and take the average.
iii. Measure dimension "M2" between the needle bearing on oil pump and the end of oil pump.
1 : Bearing race
2 : Needle bearing
3 : Oil pump assembly
A : Straightedge
CAUTION:
Measure dimension "M2" in at least three places, and take the average.
iv. Calculate dimension "M".
M = M1- M2
c. Adjust total end play "T".
1 : Bearing race
2 : Oil pump assembly
T = J - M
Total end play "T" : Refer to "Total End Play" Total End Play
- Select proper thickness of bearing race so that total end play is within specifications.
Bearing races : Refer to "Total End Play"Total End Play
49. Adjustment of front brake clearance "C".
- Measure clearance between front brake piston (1) and front brake retaining plate (2).
- Select proper thickness of front brake retaining plat so that clearance is within specifications.
a. Measure dimensions "O" and "P", and calculate dimension "N".
1 : Transmission case
2 : Front brake retaining plate
A : Straightedge
"N" : Distance between the oil pump fitting surface of transmission case and the front brake retaining plate.
N = O - P
i. Measure dimension "O" between the converter housing fitting surface of transmission case and the front brake retaining plate.
1 : Transmission case
2 : Front brake retaining plate
A : Straightedge
CAUTION:
Never change the straight edge installation position before the completion of "P" measurement.
ii. Measure dimension "P" between the converter housing fitting surface of transmission case and the oil pump fitting surface of transmission case.
1 : Transmission case
A : Straightedge
iii. Measure dimension "O" and "P" in at least three places, and take the average.
iv. Calculate dimension "N".
N = O - P
b. Measure dimensions "Q1" and "Q2", and calculate dimension "Q".
1 : Front brake piston
2 : Oil pump assembly
A : Straightedge
"Q" : Distance between the transmission case fitting surface of oil pump and the front brake piston.
Q = Q1? Q2
i. Measure dimension "Q1" between the transmission case fitting surface of oil pump and the straightedge on front brake piston.
1 : Front brake piston
2 : Oil pump assembly
A : Straightedge
CAUTION:
Measure dimension "M2" in at least three places, and take the average.
ii. Measure dimension "Q2" of the straightedge.
1 : Front brake piston
2 : Oil pump assembly
A : Straightedge
iii. Calculate dimension "Q".
Q = Q1- Q2
c. Adjust front brake clearance "C".
1 : Front brake piston
2 : Front brake retaining plate
C = N - Q
Front brake clearance "C" : Refer to "Front Brake Clearance" Front Brake Clearance
- Select proper thickness of retaining plate so that front brake clearance is within specifications.
Retaining plate : Refer to "Front Brake Clearance" Front Brake Clearance