Part 2
TRANSMISSION ASSEMBLY
Assembly (Continued)
25.Install needle bearing (1) to rear extension (2WD) or adapter case (AWD).
CAUTION:
Check the direction of needle bearing. 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.
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.
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.
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.
27.Install needle bearing to drum support.
CAUTION:
Check the direction of needle bearing. Location Of Needle Bearings And Bearing Races.
28.Install direct clutch assembly to 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 to 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 to rear carrier assembly.
CAUTION:
Check the direction of needle bearing. Location Of Needle Bearings And Bearing Races.
33.Install bearing race to rear carrier assembly.
CAUTION:
Check the direction of bearing race. Location Of Needle Bearings And Bearing Races.
34.Install rear carrier assembly to direct clutch drum.
35.Install needle bearing (rear side) to mid carrier assembly.
CAUTION:
Check the direction of needle bearing. Location Of Needle Bearings And Bearing Races.
36.Install needle bearing (front side) to mid carrier assembly.
CAUTION:
Check the direction of needle bearing. Location Of Needle Bearings And Bearing Races.
37.Install mid carrier assembly to 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. 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.
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 component part (retaining plates, drive plates and driven plate) to transmission case.
CAUTION:
Check order of plates.
46.Install needle bearing (1) to under drive carrier assembly.
CAUTION:
Check the direction of needle bearing. 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".
i.Measure dimension "K" between the converter housing fitting surface of transmission case (1) and the needle bearing mating surface of under drive sun gear (2).
CAUTION:
- Never change the straightedge (A) installation position before the completion of "L" measurement.
- Measure dimension "K" in at least three places, and take the average.
ii.Measure dimension "L" between the converter housing fitting surface of transmission case and the oil pump fitting surface of transmission case.
CAUTION:
Measure dimension "L" in at least three places, and take the average.
iii.Calculate dimension "J".
b.Measure dimensions "M1" and "M2", and calculate dimension
"M".
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.
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.
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".
- Select proper thickness of bearing race so that total end play is within specifications.
Bearing races: Total End Play.
