Assembly(1)
Assembly (1)
1. Drive manual shaft oil seals into the transmission case until it is flush using suitable tool as shown.
CAUTION:
^ Apply ATF to manual shaft oil seals.
^ Do not reuse manual shaft oil seals.
2. Install detent spring and spacer in transmission case.
Spacer bolt: 7.9 Nm (0.81 kg-m, 70 inch lbs.)
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 new retaining pin into the manual plate and manual shaft.
a. Fit pinhole of the manual plate to pinhole of the manual shaft using suitable tool.
b. Tap the new retaining pin into the manual plate using suitable tool.
CAUTION:
^ Drive retaining pin to 2 ± 0.5 mm (0.08 ± 0.020 inch) over the manual plate.
^ Do not reuse retaining pin.
7. Install new retaining pin into the transmission case and manual shaft.
a. Fit pinhole of the transmission case to pinhole of the manual shaft using suitable tool.
b. Tap the new retaining pin into the transmission case using suitable tool.
CAUTION:
^ Drive retaining pin to 5 ± 1 mm (0.20 ± 0.04 inch) over the transmission case.
^ Do not reuse retaining pin.
8. Install new 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 new 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 new 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.
Tool number: KV31102400 (J-34285 and J-34285-87)
CAUTION: Securely assemble them so that snap ring tension is slightly weak using suitable tool.
18. Install reverse brake drive plates (3), driven plates (4) and dish plates (5) in transmission case.
^ Snap ring (1)
^ Retaining plate (2)
CAUTION: Take care with order of plates.
NOTE: There are 6 drive plates and 6 driven plates.
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 inch)
Retaining plate: Refer to Specifications.
23. Install needle bearing to transmission case.
CAUTION: Apply petroleum jelly to needle bearing.
24. Install revolution sensor to transmission case.
CAUTION:
^ Do not subject it to impact by dropping or hitting it.
^ Do not disassemble.
^ Do not allow metal filings or debris to get on the sensor's front edge magnetic area.
^ Do not place in an area affected by magnetism.
Revolution sensor bolt: 5.8 Nm (0.59 kg-m, 51 inch lbs.)
25. Install return spring (1) to parking pawl (2).
26. Install parking pawl (with return spring) and pawl shaft to rear extension (2WD models) or adapter case (4WD models).
27. Install parking actuator support to rear extension (2WD models) or adapter case (4WD models).
28. Install needle bearing (1) to rear extension (2WD models) or adapter case (4WD models).
CAUTION: Apply petroleum jelly to needle bearing.
29. Install new seal rings to output shaft.
CAUTION:
^ Do not reuse seal rings.
^ Apply petroleum jelly to seal rings.
30. Install parking gear to output shaft.
31. 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.)
32. Install bearing race to output shaft.
33. 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.
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. Tighten rear extension assembly bolts to specified torque.
CAUTION: Do not reuse self-sealing bolts.
Rear extension assembly bolts: 52 Nm (5.3 kg-m, 38 ft. lbs.)
Self-sealing bolts: 61 Nm (6.2 kg-m, 45 ft. lbs.)
b. 4WD models
i. Install new 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 bolts (1) to specified torque. (With terminal bracket (2)).
CAUTION: Do not reuse self-sealing bolts (3).
Adapter case assembly bolt: 52 Nm (5.3 kg-m, 38 ft. lbs.)
Self-sealing bolt: 61 Nm (6.2 kg-m, 45 ft. lbs.)
34. 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.
35. Install needle bearing in drum support.
CAUTION: Apply petroleum jelly to needle bearing.
36. Install high and low reverse clutch assembly in direct clutch.
37. Align the drive plate using suitable tool.
38. 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 inch) beyond portion (B) of rear sun gear.
39. Install needle bearing in rear carrier assembly.
CAUTION: Apply petroleum jelly to needle bearing.
40. Install bearing race in rear carrier assembly.
CAUTION: Apply petroleum jelly to bearing race.
41. Install rear carrier assembly in direct clutch drum.
42. Install needle bearing (rear side) to mid carrier assembly.
CAUTION: Apply petroleum jelly to needle bearing.
43. Install needle bearing (front side) to mid carrier assembly.
CAUTION: Apply petroleum jelly to needle bearing.
44. Install mid carrier assembly in rear carrier assembly.
45. Install front carrier assembly, input clutch assembly and rear internal gear as a unit.
46. Install new seal rings in input clutch assembly.
CAUTION:
^ Do not reuse seal rings.
^ Apply petroleum jelly to seal rings.
47. Install new band servo anchor end pin and lock nut in transmission case.
CAUTION: Do not reuse band servo anchor end pin.
48. Install brake band in transmission case.
CAUTION: Assemble it so that identification to avoid incorrect installation faces servo side.
49. Install front sun gear to front carrier assembly.
CAUTION: Apply ATF to front sun gear bearing and 3rd one-way clutch end bearing.
50. Install needle bearing to front sun gear.
CAUTION: Apply petroleum jelly to needle bearing.
51. Adjust brake band tilting using a clips so that brake band contacts front sun gear drum evenly.
52. Adjust brake band.
a. Loosen lock nut.
b. Tighten band servo anchor end pin to specified torque.
Anchor end pin: 5.0 Nm (0.51 kg-m, 44 inch lbs.)
c. Back of band servo anchor end pin three turns.
d. Holding band servo anchor end pin, tighten lock nut to specified torque.
Lock nut: 46 Nm (4.7 kg-m, 34 ft. lbs.)