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.










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.





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.





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.






CAUTION:
Check order of plates.





15.Assemble N-spring.
16.Install reverse brake retaining plate to transmission case.





17.Install snap ring to transmission case.

CAUTION:
Be careful not to damage snap ring.





18.Measure clearance between retaining plate and snap ring. If not within specified clearance, select proper retaining plate.










19.Install needle bearing to transmission case.

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





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






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.





21.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.






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





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





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





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





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

CAUTION:
Check the direction of needle bearing. Location Of Needle Bearings And Bearing Races.
26.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 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.





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.





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.










27.Install needle bearing to drum support.

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





28.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.





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





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





31.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.





32.Install needle bearing to rear carrier assembly.

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





33.Install bearing race to rear carrier assembly.

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





34.Install rear carrier assembly to direct clutch drum.





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

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





36.Install needle bearing (front side) to mid carrier assembly.

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





37.Install mid carrier assembly to rear carrier assembly.





38.Install seal rings (1) to input clutch assembly.





39.Install needle bearing (1) to front carrier assembly.

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





40.Install input clutch assembly (with front carrier assembly and rear internal gear) (1) to transmission case.

CAUTION:
Check that the needle bearing (2) is securely positioned. If the needle bearing position is misaligned, adjust it to the specified position.