Part 2 of 3
10. Hypoid gear backlash adjustment and tooth contact check
1. Assemble the drive pinion assembly to the oil pump housing.
CAUTION:
- Be careful not to bend the shims.
- Be careful not to force the pinion against the housing bore.
2. Tighten four bolts to secure the roller bearing.
Tightening torque:
41 ± 3 Nm (4.2 ± a3 kg-m, 30.4 ± 2.2 ft. lbs.)
3. Install the oil pump housing assembly to the torque converter clutch case, and secure evenly by tightening four bolts.
Tightening torque:
41 ± 3 Nm (4.2 ± 0.3 kg-m, 30.4 ± 2.2 ft. lbs.)
CAUTION:
- Thoroughly remove the liquid gasket from the case mating surface beforehand.
- Use an old gasket or an aluminum washer so as not to damage the mating surface of the housing.
4. Rotate the drive pinion several times with ST1 and ST2.
ST1 498937100 HOLDER
ST2 499787100 WRENCH
5. Tighten the LH retainer until contact is felt while rotating the shaft. Then loosen the RH retainer. Keep tightening the LH retainer and loosening the RH retainer until the pinion shaft can no longer be turned. This is the "zero" state.
6. After the "zero" state is established, back off the LH retainer 3 teeth and secure it with the lock plate. Then back off the RH retainer and retighten until it stops. Repeat this procedure several times. Tighten the RH retainer 1-3/4 teeth further. This sets the preload. Finally, secure the retainer with its lock plate.
NOTE: Turning the retainer by one tooth changes the backlash about 0.05 mm (0.0020 inch).
7. Turn the drive pinion several rotations and check to see if the backlash is within the standard value with ST1, ST2, ST3 and ST4.
NOTE: After confirming that the backlash is correct, check the tooth contact.
ST1 499787100 WRENCH
ST2 498247001 MAGNET BASE
ST3 498247100 DIAL GAUGE
ST4 499757800 ADAPTER WRENCH
Backlash:
0.13 - 0.18 mm (0.0051 - 0.0071 inch)
8. Apply red lead evenly to the surfaces of three or four teeth of the crown gear. Rotate the drive pinion in the forward and reverse directions several times. Then remove the oil pump housing, and check the tooth contact pattern. If tooth contact is improper, readjust the backlash or shim thickness.
9. If tooth contact is correct, mark the retainer position and loosen it. After fitting the O-ring, screw in the retainer to the marked position. Then tighten the lock plate to the specified torque.
Tightening torque:
25 ± 2 Nm (2.5 ± 0.2 kg-m, 18.1 ± 1.4 ft. lbs.)
11. Install the seal pipe to the torque converter clutch case.
CAUTION: Be sure to use a new seal pipe.
12. Install two oil seals to the oil seal retainer with ST.
ST 499247300 INSTALLER
CAUTION:
- Always discard old oil seals, and install new ones.
- Pay attention to the orientation of the oil seals.
13. Attach the O-ring to the oil seal retainer with Vaseline. Install the seal to the oil pump housing bore.
CAUTION: Always discard old O-rings and install new ones.
14. Install the oil seal retainer taking care not to damage the oil seal lips. Then secure with three bolts.
NOTE: Make sure the O-ring is fitted correctly in position.
Tightening torque:
7 ± 1 Nm (0.7 ± 0.1 kg-m, 5.1 ± 0.7 ft. lbs.)
15. Apply Vaseline to the groove on the oil pump cover, and install two (R) seal rings and two (H) seal rings.
NOTE:
- Fit the seal ring after compressing, and rub Vaseline into the seal ring to avoid expansion.
- The "R" seal ring has a large diameter, while "H" has small diameter.
16. Install the rubber seal to the torque converter clutch case.
CAUTION: Be careful not to lose the rubber seal.
2. Transmission Case Section
1. Press-fit the roller bearing to the transmission case with ST
ST 398487700 DRIFT
2. Using a plastic hammer, force-fit the oil seal.
3. Install the manual plate and shaft, and secure with a spring pin.
CAUTION: Be careful not to damage the oil seal lip.
NOTE: After installation, make sure of smooth movement.
4. Assemble the manual lever and parking rod to the inside shaft, and secure with a nut.
Tightening torque:
47 ± 2 Nm (4.8 ± a2 kg-m, 34.7 ± 1.4 ft. lbs.)
5. Install inhibitor switch.
1. Install the inhibitor switch to the transmission case. Fit the projecting portion of the switch in the recessed portion of the case, and tighten three bolts temporarily.
2. Insert the range select lever into the shaft, and tighten the nut.
Tightening torque:
47 ± 5 Nm (4.8 ± 0.5 kg-m, 34.7 ± 3.6 ft. lbs.)
6. Install the detention spring.
NOTE: Position the spring so that its center is aligned with the center of the manual plate.
Tightening torque:
6 ± 1 Nm (0.6 ± 0.1 kg-m, 4.3 ± 0.7 ft. lbs.)
7. Install the lathe cut seal rings to the I.D./O.D. of the low and reverse piston. Then install the piston into the case with a press, ST1 and ST2.
ST1 398673600 COMPRESSOR
ST2 498627000 SEAT
CAUTION:
- Be careful not to tilt the piston when installing.
- Be careful not to damage the lip seal.
8. Install the one-way clutch inner race.
1. Using a press and ST1, install the needle bearing to the inner race.
ST1 398497701 INSTALLER
NOTE: Use the following ST when removing.
ST 398527700 PULLER ASSEMBLY
2. Install four seal rings and thrust washer.
CAUTION: Always discard old seal rings, and install new ones.
NOTE: Apply Vaseline to the groove of the inner race and to the seal ring after installation, so that the seal ring will not expand.
3. Place the spring retainer on the inner race. Install the spring to the recessed portion of the piston. Then tighten eight socket head bolts from the rear side of the transmission case.
CAUTION: Be sure to tighten evenly.
Tightening torque:
25 ± 2 Nm (2.5 ± 0.2 kg-m, 18.1 ± 1.4 ft. lbs.)
9. Install the band servo sub assembly.
10. Press the O.D. servo retainer into position with ST1 and ST2, and secure with a snap ring.
ST1 498677010 COMPRESSOR
ST2 399703600 PULLER ASSEMBLY
CAUTION: Perform the following operations with the transmission case set vertically on wooden blocks.
11. Measure the drive plates thickness of the low & reverse brake.
Standard value: 1.8 mm (0.071 inch)
Allowable limit. 1.6 mm (0.063 inch)
12. Installation of the low & reverse brake:
1. Install dish plate, driven plates, drive plates, and a retaining plate, and secure with a snap ring.
NOTE: Pay attention to the orientation of the dish plate.
2. Apply compressed air intermittently to check for operation.
3. Check the clearance. (Selection of retaining plate)
NOTE: Before measuring clearance, place the same thickness of shim on both sides to prevent retaining plate from tilting.
Standard value:
0.7 - 1. 0 mm (0.028 - 0.039 inch)
Allowable limit.
2.2 mm (0.067 inch)
13. Install the forward clutch drum.
1. Install carefully while rotating the forward clutch drum slowly paying special attention not to damage the seal ring.
2. Installation is completed when the forward clutch drum recedes 2.5 mm (0.098 inch) from the inner race surface.
14. Assemble the overrunning clutch hub.
CAUTION: Install thrust needle bearing in the correct direction.
NOTE:
- Join the thrust needle bearing and thrust washer with Vaseline, and then install them together.
- Make sure that the splines are engaged correctly.
15. Install the one-way clutch outer race.
NOTE: Make sure the forward clutch splines are engaged correctly.
16. Assemble the rear internal gear.
1. Join the thrust needle bearing and thrust washer to the internal gear with Vaseline, and install the internal gear while rotating it.
2. Securely engage the bearing with the dog of the overrunning clutch hub.
CAUTION: Install thrust needle bearing in the correct direction.
NOTE: Installation is complete when the snap ring top surface of the forward clutch drum recedes approximately 3.5 mm (0.138 inch).
17. Install the rear planetary carrier.
Attach the thrust needle bearing to the inside of the carrier with Vaseline. Then install the carrier while rotating slowly.
CAUTION: Install thrust needle bearing in the correct direction.
18. Install the rear sun gear.
NOTE: Install the gear with the oil groove facing up.
19. Install the front planetary carrier. Attach the thrust needle bearings to both sides of the carrier with Vaseline. Install the carrier carefully, while aligning with the splines of the forward clutch drum, and while rotating the pinion.
CAUTION: Install thrust needle bearing in the correct direction.