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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:
    • Do not reuse manual shaft oil seals.
    • Apply ATF to manual shaft oil seals.
      Fig 1: Identifying Manual Shaft Oil Seals
      G04876150
  2. Install detent spring and spacer in transmission case. Tighten detent spring and spacer bolts to the specified torque. Refer to "COMPONENTS ".
    Fig 2: Identifying Detent Spring And Spacer
    G04876082
  3. Install manual shaft to transmission case.
    Fig 3: Identifying Manual Shaft
    G04876080
  4. Install parking rod to manual plate.
    Fig 4: Identifying Parking Rod
    G04876153
  5. Install manual plate (with parking rod) to manual shaft.
    Fig 5: Identifying Manual Plate
    G04876078
  6. Install retaining pin into the manual plate and manual shaft.
    1. Fit pinhole of the manual plate to pinhole of the manual shaft with a pin punch.
    2. Use a hammer to tap the retaining pin into the manual plate.
      CAUTION:
      • Do not reuse retaining pin.
      • Drive retaining pin to 2±0.5 mm (0.08±0.020 in) over the manual plate.
        Fig 6: Identifying Retaining Pin Into Manual Plate
        G04901316
  7. Install retaining pin into the transmission case and manual shaft.
    1. Fit pinhole of the transmission case to pinhole of the manual shaft with a pin punch.
    2. Use a hammer to tap the retaining pin into the transmission case.
      CAUTION:
      • Do not reuse retaining pin.
      • Drive retaining pin to 5±1 mm (0.20±0.04 in) over the transmission case.
        Fig 7: Identifying Retaining Pin In Transmission Case And Manual Shaft
        G04876156
  8. Install O-rings to servo assembly.
    CAUTION:
    • Do not reuse O-rings.
    • Apply petroleum jelly to O-rings.
      Fig 8: Identifying O-Rings To Servo Assembly
      G04876086
  9. Install return spring to servo assembly.
    Fig 9: Identifying Return Spring
    G04876085
  10. Install servo assembly in transmission case.
    Fig 10: Identifying Servo Assembly In Transmission Case
    G04876084
  11. Using a pair of snap ring pliers, install snap ring to transmission case.
    Fig 11: Install Snap Ring
    G04876083
  12. Install D-rings in reverse brake piston.
    CAUTION:
    • Do not reuse D-rings.
    • Apply ATF to D-rings.
      Fig 12: Identifying D-Rings In Reverse Brake Piston
      G04876075
  13. Install reverse brake piston in transmission case.
    Fig 13: Identifying Reverse Brake Piston
    G04876162
  14. Install needle bearing to drum support edge surface.
    CAUTION: Apply petroleum jelly to needle bearing.
    Fig 14: Identifying Needle Bearing
    G04876073
  15. Install seal rings to drum support.
    CAUTION:
    • Do not reuse seal rings.
    • Apply petroleum jelly to seal rings.
      Fig 15: Identifying Seal Rings
      G04876072
  16. Install spring retainer and return spring in transmission case.
    Fig 16: Identifying Spring Retainer And Return Spring
    G04876071
  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.
    Fig 17: Identifying Snap Ring (Fixing Spring Retainer) In Transmission Case
    G04876166
  18. Install reverse brake drive plates, driven plates and dish plates in transmission case.
    CAUTION: Take care with order of plates.
    • Snap ring (1)
    • Retaining plate (2)
    • Drive plate (3)
    • Driven plate (4)
    • Dish plate (5)
    • Drive plate/Driven plate: 6/6
      Fig 18: Identifying Reverse Brake Drive Plates, Driven Plates And Dish Plates In Transmission Case
      G04898282
  19. Assemble N-spring.
  20. Install reverse brake retaining plate in transmission case.
    Fig 19: Assembling N-Spring
    G04876168
  21. Install snap ring in transmission case.
    Fig 20: Identifying Snap Ring In Transmission Case
    G04876169
  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 "REVERSE BRAKE ".

    Fig 21: Measuring Clearance Between Retaining Plate And Snap Ring
    G04876170
  23. Install needle bearing to transmission case.
    CAUTION:
  24. Install revolution sensor to transmission case. Tighten revolution sensor bolt to the specified torque. Refer to "COMPONENTS ".
    CAUTION:
    • Do not subject it to impact by dropping or hitting it.
    • Do not disassemble.
    • Do not allow metal filings, etc., to get on the sensor's front edge magnetic area.
    • Do not place in an area affected by magnetism.
      Fig 23: Identifying Revolution Sensor
      G04876066
  25. Assemble one of the following parts.
    • Rear extension assembly (VQ35DE models for 2WD)
    • Adapter case assembly (AWD models)
    • Output shaft & companion flange complement (VK45DE models for 2WD)
    1. VQ35DE models 
      1. As shown in the figure, use the drift to drive rear oil seal into the rear extension (2WD models) or adapter case (AWD models) until it is flush.
        CAUTION:
        • Apply ATF to rear oil seal.
        • Do not reuse rear oil seal.
          Fig 24: Tapping Rear Extension Assembly (VQ35DE Models For 2WD)
          G05218435
      2. Install return spring (1) to parking pawl (2).
        Fig 25: Identifying Return Spring And Parking Pawl
        G04875965
      3. Install parking pawl (with return spring) and pawl shaft to rear extension (2WD models) or adapter case (AWD models).
        Fig 26: Identifying Parking Pawl And Pawl Shaft
        G04875964
      4. Install parking actuator support from rear extension (2WD models) or adapter case (AWD models).
        Fig 27: Identifying Parking Actuator Support
        G04875963
      5. Install needle bearing (1) to rear extension (2WD models) or adapter case (AWD models).
        CAUTION:

        Refer to GI section to make sure icons (symbol marks) in the figure.  Refer to "COMPONENTS ".

        Fig 28: Identifying Needle Bearing
        G04875973
    2. VK45DE models 
      1. Install return spring (1) to parking pawl (2).
        Fig 29: Identifying Return Spring And Parking Pawl
        G04875965
      2. Install parking pawl (with return spring) (1) and pawl shaft (2) to output shaft & companion flange complement.
        Fig 30: Installing Parking Pawl And Pawl Shaft From Output Shaft
        G05213443
      3. Install parking actuator support (1) from output shaft & companion flange complement.
        Fig 31: Installing Parking Actuator Support To Output Shaft And Companion Flange Complement
        G05213442
  26. Assemble one of the following parts.
    • Rear extension assembly (VQ35DE models for 2WD)
    • Adapter case assembly (AWD models)
    • Output shaft & companion flange complement (VK45DE models for 2WD)
    1. VQ35DE models for 2WD 
      1. Install seal rings to output shaft.
        CAUTION:
        • Do not reuse seal rings.
        • Apply petroleum jelly to seal rings.
          Fig 32: Identifying Seal Rings On Output Shaft
          G04875961
      2. Install parking gear to output shaft.
        Fig 33: Identifying Parking Gear And Output Shaft
        G04875960
      3. 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.)
        Fig 34: Identifying Output Shaft In Transmission Case
        G04876062
      4. Install bearing race to output shaft.
        Fig 35: Identifying Bearing Race In Output Shaft
        G04875958
      5. Apply recommended sealant (Genuine Anaerobic Liquid Gasket or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".) to rear extension assembly as shown in the figure.
        CAUTION: Completely remove all moisture, oil and old sealant, etc. from the transmission case and rear extension assembly mounting surfaces.
        Fig 36: Applying Recommended Sealant
        G04901343
      6. 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.
        Fig 37: Identifying Rear Extension Assembly
        G04876060
      7. Tighten rear extension assembly bolts to the specified torque. Refer to "COMPONENTS ".
        CAUTION: Do not reuse self-sealing bolts.
        Fig 38: Identifying Bolts For Rear Extension Assembly And Transmission Case
        G04875955
    2. VK45DE models for 2WD 
      1. Install seal rings to intermediate shaft.
        CAUTION:
        • Do not reuse seal rings.
        • Apply petroleum jelly to seal rings.
          Fig 39: Identifying Seal Rings To Intermediate Shaft
          G05213567
      2. 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.)
        Fig 40: Installing Intermediate Shaft From Transmission Case By Rotating Left/Right
        G05213566
      3. Apply recommended sealant (Genuine Anaerobic Liquid Gasket or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".) 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.
        Fig 41: Applying Recommended Sealant
        G04901343
      4. 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.
        Fig 42: Installing Output Shaft And Companion Flange
        G05213565
      5. Tighten output shaft & companion flange complement bolts (1) to the specified torque. Refer to "COMPONENTS ".

        : Bolt (10)

        CAUTION: Do not reuse self-sealing bolts (2).

        Refer to GI section to make sure icons (symbol marks) in the figure.  Refer to "COMPONENTS ".

        Fig 43: Locating Self-Sealing Bolts
        G05213439
    3. AWD models 
      1. Install seal rings to output shaft.
        CAUTION:
        • Do not reuse seal rings.
        • Apply petroleum jelly to seal rings.
          Fig 44: Identifying Seal Rings On Output Shaft
          G04875961
      2. Install parking gear to output shaft.
        Fig 45: Identifying Parking Gear And Output Shaft
        G04875960
      3. 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.)
        Fig 46: Identifying Output Shaft In Transmission Case
        G04876062
      4. Install bearing race to output shaft.
        Fig 47: Identifying Bearing Race In Output Shaft
        G04875958
      5. 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.
        • Do not reuse gasket.
          Fig 48: Identifying Gasket Onto Transmission Case
          G04901220
      6. 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.
        Fig 49: Identifying Adapter Case Assembly To Transmission Case
        G04898168
      7. Tighten adapter case assembly bolts (1) to the specified torque. [With bracket (2).] Refer to "COMPONENTS ".

        : Bolt (10)

        CAUTION: Do not reuse self-sealing bolts (3).

        Refer to GI section to make sure icons (symbol marks) in the figure.  Refer to "COMPONENTS ".

        Fig 50: Locating Adapter Case Assembly And Transmission Case
        G05218771
  27. Install needle bearing in drum support.
    CAUTION:
  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.
    Fig 52: Identifying Direct Clutch Assembly
    G04876040
  29. Install high and low reverse clutch assembly in direct clutch.
    Fig 53: Identifying High And Low Reverse Clutch Assembly
    G04876039
  30. Using a flat-bladed screwdriver, align the drive plate.
    Fig 54: Aligning Drive Plate
    G04876188
  31. Install high and low reverse clutch hub, mid sun gear assembly and rear sun gear assembly as a unit.
    Fig 55: Identifying High And Low Reverse Clutch Hub
    G04876038
    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.
    Fig 56: Checking Portion Of High And Low Reverse Clutch Drum
    G04876190
  32. Install needle bearing in rear carrier assembly.
    CAUTION:
  33. Install bearing race in rear carrier assembly.
    CAUTION: Apply petroleum jelly to bearing race.
    Fig 58: Identifying Bearing Race In Rear Carrier Assembly
    G04876036
  34. Install rear carrier assembly in direct clutch drum.
    Fig 59: Identifying Rear Carrier Assembly
    G04876193
  35. Install needle bearing (rear side) to mid carrier assembly.
    CAUTION:
  36. Install needle bearing (front side) to mid carrier assembly.
    CAUTION:
  37. Install mid carrier assembly in rear carrier assembly.
    Fig 62: Identifying Mid Carrier Assembly In Rear Carrier Assembly
    G04876032
  38. Install front carrier assembly, input clutch assembly and rear internal gear as a unit.
    Fig 63: Identifying Front Carrier Assembly And Input Clutch Assembly
    G04876028
  39. Install seal rings in input clutch assembly.
    CAUTION:
    • Do not reuse seal rings.
    • Apply petroleum jelly to seal rings.
      Fig 64: Identifying Seal Rings In Input Clutch Assembly
      G04876027
  40. Install band servo anchor end pin and lock nut in transmission case.
    CAUTION: Do not reuse band servo anchor end pin.
    Fig 65: Identifying Band Servo Anchor End Pin And Lock Nut In Transmission Case
    G04876029
  41. Install brake band in transmission case.
    CAUTION: Assemble it so that identification to avoid incorrect installation faces servo side.
    Fig 66: Identifying Brake Band In Transmission Case
    G04876200
  42. Install front sun gear to front carrier assembly.
    CAUTION: Apply ATF to front sun gear bearing and 3rd one-way clutch end bearing.
    Fig 67: Identifying Front Sun Gear Assembly
    G04876026
  43. Install needle bearing to front sun gear.
    CAUTION: Apply petroleum jelly to needle bearing.
    Fig 68: Identifying Needle Bearing
    G04876025
  44. Adjust brake band tilting using a clip so that brake band contacts front sun gear drum evenly.
    Fig 69: Identifying Brake Band
    G04876203
  45. Adjust brake band.
    1. Loosen lock nut.
    2. Tighten band servo anchor end pin to specified torque.

      : 5.0 N.m (0.51 kg-m, 44 in-lb) 

      Fig 70: Identifying Brake Band In Transmission Case
      G04876200
    3. Back of band servo anchor end pin three turns.
    4. Holding band servo anchor end pin, tighten lock nut to the specified torque. Refer to "COMPONENTS ".
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