Adjustment 1

ADJUSTMENT

Differential side bearing preload




1. Install differential side bearing outer race without adjusting shim on transmission case.
2. Install differential side bearing outer race on converter housing.





3. Place final drive assembly on transmission case.
4. Install transmission case on converter housing and tighten transmission case fixing bolts to the specified torque.

- RE4F04A -





5. Attach dial indicator on differential case at converter housing side.
6. Insert Tool into differential side gear from transmission case side.
7. Move Tool up and down and measure dial indicator deflection.

- RE4F04V -





5. Set Tool on differential case at converter housing side and attach dial indicator on Tool.
6. Insert the other Tool viscous coupling from transmission case side.
7. Move Tool up and down and measure dial indicator deflection.

- RE4F04A and RE4F04V -

8. Select proper thickness of differential side bearing adjusting shim(s).

Suitable shim thickness = Dial indicator deflection + Specified bearing preload

Differential side bearing adjusting shim:





Bearing preload: 0.05 -0.09 mm (0.0020-0.0035 in)





9. Remove converter housing from transmission case.
10. Remove final drive assembly from transmission case.
11. Remove differential side bearing outer race from transmission case.
12. Reinstall differential side bearing outer race and shim(s) selected from SDS table on transmission case.
13. Reinstall converter housing on transmission case and tighten transmission case fixing bolts to the specified torque.





14. Insert Tool into viscous coupling and measure turning torque of final drive assembly.
- When measuring turning torque, turn final drive assembly in both directions several times to seat bearing rollers correctly.

Turning torque of final drive assembly (New bearing):
0.18-1.37 N.m (8.0- 14.0 kg-cm, 6.9- 12.2 in-lb)

- When old bearing is used again, turning torque will be slightly less than the above.
- Make sure torque is close to the specified range.

Reduction gear bearing preload





1. Remove transmission case and final drive assembly from converter housing.
2. Select proper thickness of reduction gear bearing adjusting shim using the following procedures.
a. Place reduction gear on transmission case as shown.





b. Place idler gear bearing on transmission case.
c. Measure dimensions "B" "C" and "D" and calculate dimension "A".

A = D (B + C)
"A": Distance between the surface of idler gear bearing inner race and the adjusting shim mating surface of reduction gear.





- Measure dimension "B" between the end of reduction gear and the surface of transmission case.
- Measure dimension "B" in at least two places.





- Measure dimension "C" between the surface of idler gear bearing inner race and the surface of transmission case.
- Measure dimension "C" in at least two places.





- Measure dimension "D" between the end of reduction gear and the adjusting shim mating surface of reduction gear.
- Measure dimension "D" in at least two places.
- Calculate dimension "A" A = D - (B + C)





d. Measure dimension "E" between the end of idler gear and the idler gear bearing inner race mating surface of idler gear.
- Measure dimension "E" in at least two places.
e. Select proper thickness of reduction gear bearing adjusting shim.

Proper shim thickness = A - E - 0.5 mm (0.0020 in)*
(* ...Bearing preload)

Reduction gear bearing adjusting shim:












3. Install reduction gear and reduction gear bearing adjusting shim selected in step 2-e on transmission case.
4. Press idler gear bearing inner race on idler gear.
5. Press idler gear on reduction gear.
- Press idler gear so that idler gear can be locked by parking pawl.





6. Tighten idler gear lock nut to the specified torque.
- Lock idler gear with parking pawl when tightening lock nut.





7. Measure turning torque of reduction gear.
- When measuring turning torque, turn reduction gear in both directions several times to seat bearing rollers correctly.

Turning torque of reduction gear:
0.05 -0.39 N~m (0.5 - 4.0 kg-cm, 0.43-3.47 in-lb)

- If turning torque is out of specification, decrease or increase thickness of reduction gear bearing adjusting shim.





8. After properly adjusting turning torque, clinch idler gear lock nut as shown.





Output shaft end play
- Measure clearance between side cover and the end of the output shaft bearing.
- Select proper thickness of adjusting shim so that clearance is within specifications.





1. Install bearing retainer for output shaft.





2. Install output shaft thrust needle bearing on bearing retainer.





3. Install output shaft on transmission case.





4. Measure dimensions "l1" and "l2" at side cover and then calculate dimension "A".
- Measure dimension "l1" and "l2" in at least two places.

"A": Distance between transmission case fitting surface and adjusting shim mating surface.

A = l1 - l2 l2: Height of gauge





5. Measure dimensions "l2" and "l3" and then calculate dimension "B".

Measure "l2" and "l3" in at least two places.

"B": Distance between the end of output shaft bearing outer race and the side cover fitting surface of transmission case.

B = l2 - l3 Height of gauge





6. Select proper thickness of adjusting shim so that output shaft end play (clearance between side cover and output shaft bearing) is within specifications.

Output shaft end play (A - B): 0 -0.15 mm (0 - 0.0059 in)

Output shaft end play adjusting shim:





7. Install adjusting shim on output shaft bearing.