Part 1

TRANSMISSION ASSEMBLY


Assembly






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:
- Never reuse manual shaft oil seals.
- Apply ATF to manual shaft oil seals.





2. Install detent spring to transmission case. Tighten detent spring bolt to the specified torque.

Black Arrow :Bolt






3. Install manual shaft to transmission case.





4. Install parking rod (1) to manual plate (2).





5. Install manual plate (with parking rod) to manual shaft.





6. Install retaining pin (1) into the manual plate and manual shaft.
a. Fit pinhole of the manual plate to pinhole of the manual shaft with a pin punch.
b. Use a hammer to tap the retaining pin into the manual plate.

A : Approx. 2 mm (0.08in)

CAUTION:
Drive retaining pin to 2�0.5 mm (0.08�0.020 in) over the manual plate.





7. Install retaining pin into the transmission case and manual shaft.
a. Fit pinhole of the transmission case to pinhole of the manual shaft with a pin punch.
b. 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.





8. Install D-rings to reverse brake piston.





9. Install reverse brake piston to transmission case.





10. Install needle bearing to drum support edge surface.

CAUTION:
Check the direction of needle bearing. Location Of Needle Bearings And Bearing Races, "Location of Needle Bearings and Bearing Races".





11. Install seal rings to drum support.





12. Install reverse brake spring retainer and reverse brake return spring to transmission case.





13. Set the clutch spring compressor 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.





14. Install reverse brake component part (drive plates, driven plates, dish plates and retaining plate) to transmission case.

1 : Snap ring
2 : Retaining plate
3 : Drive plate (six pieces)
4 : Driven plate (six pieces)
5 : Dish plate
6 : Dish plate

CAUTION:
Check order of plates.





15. Assemble N-spring.





16. Install snap ring to transmission case.

CAUTION:
Be careful not to damage snap ring.





17. 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.
Retaining plate: Refer to Reverse Brake Clearance







18. Install needle bearing to transmission case.

CAUTION:
Check the direction of needle bearing. Oil Channel Location Of Needle Bearings And Bearing Races, "Location of Needle Bearings and Bearing Races".





19. Install output speed sensor (1) to transmission case. Tighten revolution sensor bolt to the specified torque.

Black Arrow :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.





20. As shown in the figure, use the drift to drive rear oil seal into the rear extension (2WD) (A) or adapter case (AWD) (B) until it is flush.

1 : Drift [SST: 33400001 (J-26082)]
2 : Drift [Commercial service tool �64 mm (2.52 in)]


CAUTION:
- Never reuse rear oil seal.
- Apply ATF to rear oil seal.





21. Install return spring (1) to parking pawl (2).





22. Install parking pawl (with return spring) and pawl shaft to rear extension (2WD) or adapter case (AWD).





23. Install parking actuator support to rear extension (2WD) or adapter case (AWD).





24. Install needle bearing (1) to rear extension (2WD) or adapter case (AWD).

CAUTION:
Check the direction of needle bearing. Oil Channel Location Of Needle Bearings And Bearing Races, "Location of Needle Bearings and Bearing Races".
25. 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 to 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 (Genuine Anaerobic Liquid Gasket or equivalent. Recommended Chemical Products And Sealants.) to rear extension assembly as shown in the figure.

Sealant starting point and endpoint (A) : Start and finish point shall be in the center of two bolts.
Overlap width of sealant starting point and endpoint (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.





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.

A : Bolt
B : Self-sealing bolt

b. AWD
i. Install seal rings (1) to output shaft.





ii. Install parking gear (1) to output shaft (2).





iii. 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.)





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.
- Never reuse gasket.





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.

1 : Bracket
A : Bolt
B : Self-sealing bolt






26. Install needle bearing to drum support.

CAUTION:
Check the direction of needle bearing. Oil Channel Location Of Needle Bearings And Bearing Races, "Location of Needle Bearings and Bearing Races".





27. 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.





28. Install high and low reverse clutch assembly to direct clutch.





29. Align the drive plate using a flat-bladed screwdriver.





30. 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.





31. Install needle bearing to rear carrier assembly.

CAUTION:
Check the direction of needle bearing. Oil Channel Location Of Needle Bearings And Bearing Races, "Location of Needle Bearings and Bearing Races".





32. Install bearing race to rear carrier assembly.

CAUTION:
Check the direction of needle bearing. Oil Channel Location Of Needle Bearings And Bearing Races, "Location of Needle Bearings and Bearing Races".





33. Install rear carrier assembly to direct clutch drum.





34. Install needle bearing (rear side) to mid carrier assembly.

CAUTION:
Check the direction of needle bearing. Oil Channel Location Of Needle Bearings And Bearing Races, "Location of Needle Bearings and Bearing Races".