Transmission Assembly: Assembly
- As shown in the figure below, 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:
- Never reuse manual shaft oil seals.
- Apply ATF to manual shaft oil seals.
- Install detent spring to transmission case. Tighten detent spring bolt to the specified torque.
: Bolt - Install manual shaft to transmission case.
- Install parking rod
to manual plate
.
- Install manual plate (with parking rod) to manual shaft.
- Install retaining pin
into the manual plate and manual shaft.
- Install retaining pin into the transmission case and manual shaft.
- Fit pinhole of the transmission case to pinhole of the manual shaft with a pin punch.
- Use a hammer to tap the retaining pin into the transmission case.CAUTION:
Drive retaining pin to 5+-1 mm (0.20+-0.04 in) over the transmission case.
- Install D-rings to reverse brake piston.
- Install reverse brake piston to transmission case.
- Install needle bearing to drum support edge surface.CAUTION:
Check the direction of needle bearing. Refer to LOCATION OF NEEDLE BEARINGS AND BEARING RACES .
- Install seal rings to drum support.
- Install reverse brake spring retainer and reverse brake return spring to transmission case.
- Set the clutch spring compressor [SST: KV31102400 (J-34285 and J-34285-87)] (A) on reverse brake spring retainer and install snap ring (fixing spring retainer)
to transmission case while compressing return spring.
CAUTION:- Securely assemble them using a flat-bladed screwdriver so that snap ring tension is slightly weak.
- Be careful not to damage snap ring.
- Install reverse brake component part (drive plates, driven plates, and dish plates) to transmission case.
: Snap Ring : Retaining Plate : Drive Plate (Six Pieces) : Driven Plate (Six Pieces) : Dish Plate : Dish Plate CAUTION:Check order of plates.
- Assemble N-spring.
- Install reverse brake retaining plate to transmission case.
- Install snap ring to transmission case.CAUTION:
Be careful not to damage snap ring.
- Measure clearance between retaining plate and snap ring. If not within specified clearance, select proper retaining plate.
Specified clearance (A) Standard: Refer to REVERSE BRAKE CLEARANCE or REVERSE BRAKE CLEARANCE . Retaining plate: Refer to REVERSE BRAKE CLEARANCE or REVERSE BRAKE CLEARANCE . - Install needle bearing to transmission case.CAUTION:
Check the direction of needle bearing. Refer to LOCATION OF NEEDLE BEARINGS AND BEARING RACES .
- Install output speed sensor
to transmission case. Tighten output speed sensor bolt to the specified torque.
: Bolt CAUTION:- Never subject it to impact by dropping or hitting it.
- Never disassemble.
- Never allow metal filings, etc. to get on the sensor's front edge magnetic area.
- Never place in an area affected by magnetism.
- As shown in the figure below, use the drift to drive rear oil seal into the rear extension (2WD)
or adapter case (AWD)
until it is flush.
(1) : Drift [SST: 33400001 (J-26082)] (2) : Drift [Commercial service tool Ø64 mm (2.52 in)] CAUTION:- Never reuse rear oil seal.
- Apply ATF to rear oil seal.
- Install return spring
to parking pawl
.
- Install parking pawl (with return spring) and pawl shaft to rear extension (2WD) or adapter case (AWD).
- Install parking actuator support to rear extension (2WD) or adapter case (AWD).
- Install needle bearing
to rear extension (2WD) or adapter case (AWD).
CAUTION:Check the direction of needle bearing. Refer to LOCATION OF NEEDLE BEARINGS AND BEARING RACES .
- Install rear extension assembly (2WD) or adapter case assembly (AWD) according to the following procedures.
- 2WD
- Install seal rings
to output shaft.
- Install parking gear
to output shaft
.
- Install output shaft to transmission case.CAUTION:
Be careful not to mistake front for rear because both sides looks similar. (Thinner end is front side.)
- Install bearing race to output shaft.
- Apply recommended sealant to rear extension assembly as shown in the figure below.
*
: Genuine Anaerobic Liquid Gasket or equivalent. Refer to RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS . Sealant starting point and end-point : Start and finish point shall be in the center of two bolts. Overlap width of sealant starting point and end-point (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.
- 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.
- Tighten rear extension assembly bolts to the specified torque.
: Bolt
- Install seal rings
- AWD
- Install seal rings
to output shaft.
- Install parking gear
to output shaft
.
- Install output shaft to transmission case.CAUTION:
Be careful not to mistake front for rear because both sides looks similar. (Thinner end is front side.)
- Install bearing race to output shaft.
- 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.
- 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.
- Tighten adapter case assembly bolts to the specified torque.
: Bracket : Bolt
- Install seal rings
- 2WD
- Install needle bearing to drum support.CAUTION:
Check the direction of needle bearing. Refer to LOCATION OF NEEDLE BEARINGS AND BEARING RACES .
- 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.
- Install high and low reverse clutch assembly to direct clutch.
- Align the drive plate using a flat-bladed screwdriver.
- 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.
- Install needle bearing to rear carrier assembly.CAUTION:
Check the direction of needle bearing. Refer to LOCATION OF NEEDLE BEARINGS AND BEARING RACES .
- Install bearing race to rear carrier assembly.CAUTION:
Check the direction of needle bearing. Refer to LOCATION OF NEEDLE BEARINGS AND BEARING RACES .
- Install rear carrier assembly to direct clutch drum.
- Install needle bearing (rear side) to mid carrier assembly.CAUTION:
Check the direction of needle bearing. Refer to LOCATION OF NEEDLE BEARINGS AND BEARING RACES .
- Install needle bearing (front side) to mid carrier assembly.CAUTION:
Check the direction of needle bearing. Refer to LOCATION OF NEEDLE BEARINGS AND BEARING RACES .
- Install mid carrier assembly to rear carrier assembly.
- Install seal rings
to input clutch assembly.
- Install needle bearing
to front carrier assembly.
CAUTION:Check the direction of needle bearing. Refer to LOCATION OF NEEDLE BEARINGS AND BEARING RACES .
- Install input clutch assembly (with front carrier assembly and rear internal gear)
to transmission case.
CAUTION:Check that the needle bearing
is securely positioned. If the needle bearing position is misaligned, adjust it to the specified position.
- Install 1st one-way clutch
to front brake hub (with under drive carrier)
.
- Check operation of 1st one-way clutch.
- Install under drive carrier (with 1st one-way clutch)
to transmission case.
- Install snap ring
to transmission case.
CAUTION:Be careful not to damage snap ring.
- Install front brake component part (retaining plates, drive plates, and driven plate) to transmission case.
: Retaining plate (thin) : Drive Plate : Driven Plate : Retaining Plate (Thick) : Front CAUTION:Check order of plates.
- Install needle bearing
to under drive carrier assembly.
CAUTION:Check the direction of needle bearing. Refer to LOCATION OF NEEDLE BEARINGS AND BEARING RACES .
- Install under drive sun gear
to under drive carrier assembly.
- Adjustment of total end play "T".
- Measure clearance between bearing race
and oil pump cover
.
- Select proper thickness of bearing race so that end play is within specifications.
- Measure dimensions "K" and "L", and calculate dimension "J".
: Transmission Case : 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 - 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 straightedge (A) installation position before the completion of "L" measurement.
- Measure dimension "K" in at least three places, and take the average.
- Measure dimension "L" between the converter housing fitting surface of transmission case and the oil pump fitting surface of transmission case.
: Transmission Case (A) : Straightedge CAUTION:Measure dimension "L" in at least three places, and take the average.
- Measure dimension "K" and "L" in at least three places, and take the average.
- Calculate dimension "J".
J = K - L
- Measure dimension "K" between the converter housing fitting surface of transmission case and the needle bearing mating surface of under drive sun gear.
- Measure dimensions "M1
" and "M2
", and calculate dimension "M".
: Bearing Race : Needle Bearing : 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 - Place bearing race
and needle bearing
on oil pump assembly
.
- Measure dimension "M1
" between the transmission case fitting surface of oil pump and the end of oil pump.
: Bearing race : Needle bearing : Oil pump assembly (A) : Straightedge CAUTION:Measure dimension "M1 " in at least three places, and take the average.
- Measure dimension "M2
" between the needle bearing on oil pump and the end of oil pump.
: Bearing Race : Needle Bearing : Oil Pump Assembly (A) : Straightedge CAUTION:Measure dimension "M2 " in at least three places, and take the average.
- Calculate dimension "M".
M = M1 - M2
- Place bearing race
- Adjust total end play "T".
: Bearing Race : Oil Pump Assembly T = J - M Total End Play "T" : Refer to TOTAL END PLAY or TOTAL END PLAY . - Select proper thickness of bearing race so that total end play is within specifications.
Bearing Races : Refer to TOTAL END PLAY or TOTAL END PLAY .
- Select proper thickness of bearing race so that total end play is within specifications.
- Measure clearance between bearing race
- Adjustment of front brake clearance "C".
- Measure clearance between front brake piston
and front brake retaining plate
.
- Select proper thickness of front brake retaining plat so that clearance is within specifications.
- Measure dimensions "O" and "P", and calculate dimension "N".
: Transmission case : 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 - Measure dimension "O" between the converter housing fitting surface of transmission case
and the front brake retaining plate
.
CAUTION:- Never change the straightedge (A) installation position before the completion of "P" measurement.
- Measure dimension "O" in at least three places, and take the average.
- Measure dimension "P" between the converter housing fitting surface of transmission case and the oil pump fitting surface of transmission case.
: Transmission case (A) : Straightedge CAUTION:Measure dimension "P" in at least three places, and take the average.
- Calculate dimension "N".
N = O - P
- Measure dimension "O" between the converter housing fitting surface of transmission case
- Measure dimensions "Q1
" and "Q2
", and calculate dimension "Q".
: Front Brake Piston : Oil Pump Assembly (A) : Straightedge "Q" : Distance between the transmission case fitting surface of oil pump and the front brake piston. Q = Q1 - Q2 - Measure dimension "Q1
" between the transmission case fitting surface of oil pump and the straightedge on front brake piston.
: Front Brake Piston : Oil Pump Assembly (A) : Straightedge CAUTION:Measure dimension "Q1 " in at least three places, and take the average.
- Measure dimension "Q2
" of the straightedge.
: Front Brake Piston : Oil Pump Assembly (A) : Straightedge - Calculate dimension "Q".
Q = Q1 - Q2
- Measure dimension "Q1
" between the transmission case fitting surface of oil pump and the straightedge on front brake piston.
- Adjust front brake clearance "C".
: Front Brake Piston : Front Brake Retaining Plate C = N - Q Front brake clearance "C" : Refer to FRONT BRAKE CLEARANCE or FRONT BRAKE CLEARANCE . - Select proper thickness of retaining plate so that front brake clearance is within specifications.
Retaining plate : Refer to FRONT BRAKE CLEARANCE or FRONT BRAKE CLEARANCE .
- Select proper thickness of retaining plate so that front brake clearance is within specifications.
- Measure clearance between front brake piston
- Remove under drive sun gear
from under drive carrier assembly.
- Install needle bearing
to under drive sun gear.
CAUTION:Check the direction of needle bearing. Refer to LOCATION OF NEEDLE BEARINGS AND BEARING RACES .
- Install O-ring
to oil pump assembly.
- Install seal ring
to oil pump assembly.
- Install bearing race
to oil pump assembly.
- Install under drive sun gear (with needle bearing)
to oil pump assembly
.
- Install oil pump assembly (with under drive sun gear) to transmission case.CAUTION:
Apply ATF to oil pump bearing.
- Apply recommended sealant to oil pump assembly as shown in the figure below.
: Genuine RTV silicone sealant or equivalent. Refer to RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS . CAUTION:Completely remove all moisture, oil and old sealant, etc. from the oil pump mounting bolts and oil pump mounting bolt mounting surfaces.
- Tighten oil pump bolts (
) to the specified torque.
- Install O-ring to input clutch assembly.
- Install converter housing to transmission case, and tighten converter housing bolts (
) to the specified torque.
- Connect TCM connector
to joint connector.
- Install joint connector
to the Control Valve & TCM.
CAUTION:Apply ATF to O-ring of joint connector.
- Install the Control Valve & TCM
to transmission case.
CAUTION:- Make sure that input speed sensor securely installs input speed sensor holes
.
- Hang down output speed sensor harness toward outside so as not to disturb installation of the Control Valve & TCM.
- Adjust joint connector of the Control Valve & TCM to terminal hole of transmission case.
- Assemble it so that manual valve cutout is engaged with manual plate projection.
- Make sure that input speed sensor securely installs input speed sensor holes
- Install bolts and clip
to the Control Valve & TCM. Tighten bolt
to the specified torque before tightening the other than bolts.
: Front Bolt Symbol Length mm (in) Number Of Bolts 43 (1.69) 3 40 (1.57) 2 54 (2.13) 6 50 (1.97) 2 *
50 (1.97) 1 *: Reamer bolt
- Connect output speed sensor connector (A).
- Engage output speed sensor harness with terminal clips (
).
- Pull down joint connector
.
CAUTION:Be careful not to damage connector.
- Install snap ring
to joint connector
.
- Install magnets
to oil pan.
- Install oil pan gasket to transmission case.CAUTION:
- Never reuse oil pan gasket.
- Install it in the direction to align hole positions.
- Completely remove all moisture, oil and old gasket, etc. from oil pan gasket mounting surface.
- Install oil pan
to transmission case.
: Front : Oil pan mounting bolt CAUTION:- Be careful not to pinch harnesses.
- Completely remove all moisture, oil and old gasket, etc. from oil pan mounting surface.
- Tighten oil pan mounting bolts to the specified torque in numerical order shown in the figure below after temporarily tightening them. Tighten oil pan mounting bolts to the specified torque.
: Front CAUTION:Never reuse oil pan mounting bolts.
- Install drain plug to oil pan. Tighten drain plug to the specified torque.CAUTION:
Never reuse drain plug gasket.
- Pour ATF into torque converter.
- Approximately 2 liter (2-1/8 US qt, 1-3/4 Imp qt) of ATF is required for a new torque converter.
- When reusing old torque converter, add the same amount of ATF as was drained.
- Install torque converter while aligning notches of torque converter with notches of oil pump.CAUTION:
Install torque converter while rotating it.
- Measure dimension "A" to make sure that torque converter is in proper position.
(B) : Scale (C) : Straightedge Dimension (A) : Refer to TORQUE CONVERTER or TORQUE CONVERTER .