Assembly 2

ASSEMBLY 2





1. Apply locking sealant (Loctite #518) to transmission case as shown in illustration.





2. Set side cover on transmission case.
- Apply locking sealant to the mating surface of transmission case.





3. Tighten side cover fixing bolts to specified torque.

3.0 - 3.4 Nm (0.31 - 0.35 kg.m, 26.9 - 30.4 inch lbs.)

- Do not mix bolts (A) and (B).
- Always replace bolts (A) as they are self-sealing bolts.
4. Remove paper rolled around bearing retainer.





5. Install thrust washer on bearing retainer.
- Apply petroleum jelly to thrust washer.





6. Install forward clutch assembly.
- Align teeth of low & reverse brake drive plates before installing.
- Make sure that bearing retainer seal rings are not spread.
- If forward clutch assembly is correctly seated, points (1) and (2) are at almost same level.





7. Install thrust needle bearing on bearing retainer.
- Apply petroleum jelly to thrust needle bearing.
- Pay attention to direction of thrust needle bearing.





8. Install overrun clutch hub.
- Apply petroleum jelly to thrust washers.
- Align teeth of overrun clutch drive plates before installing.





9. Hold forward clutch hub and turn rear internal gear. Check overrun clutch hub for correct directions of lock and unlock.
- If not shown as illustrated, check installed direction of forward one-way clutch.





10. Install forward clutch hub and rear internal gear assembly.
- Align teeth of forward clutch drive plates before installing.
- Check that three hooks of thrust washer are correctly aligned after installing.





11. Install rear planetary carrier assembly and rear sun gear according to the following procedures.
a. Install needle bearings on rear planetary carrier.
- Apply petroleum jelly to needle bearings.
- Pay attention to direction of needle bearings.





b. Install rear sun gear on rear planetary carrier.
- Pay attention to direction of rear sun gear.





c. Install rear planetary carrier on transmission case.





12. Install thrust needle bearing on front planetary carrier, then install them together on transmission case.
- Apply petroleum jelly to thrust needle bearing.
- Pay attention to direction of thrust needle bearing.
13. Install low and reverse brake piston according to the following procedures.





a. Set and align return springs to transmission case gutters as shown in illustration.





b. Set and align piston with retainer.





c. Install piston and retainer assembly on the transmission case.
- Align bracket to specified gutter as indicated in illustration.





d. Check that each protrusion of piston is correctly set to corresponding return spring as follows.
- Push piston and retainer assembly evenly and confirm they move smoothly.
- If they can not move smoothly, remove piston and retainer assembly and align return spring correctly as instructed in step "a".





e. Push down piston and retainer assembly and install snap ring.





14. Install low one-way clutch to front planetary carrier by turning carrier in the direction of the arrow shown.





15. Install snap ring with screwdriver.
- Forward clutch and bearing must be correctly installed for snap ring to fit into groove of transmission case.





16. Install needle bearing on transmission case.
- Apply petroleum jelly to needle bearing.
- Pay attention to direction of needle bearing.





17. Install bearing race, needle bearing and high clutch hub on front sun gear.
- Apply petroleum jelly to needle bearing.
- Pay attention to direction of needle bearing.





18. Install needle bearing and high clutch drum on high clutch hub.





19. Install needle bearing on high clutch drum.
- Apply petroleum jelly to needle bearing.
- Pay attention to direction of needle bearing.
20. Remove paper rolled around input shaft.





21. Install input shaft assembly in reverse clutch.
- Align teeth of reverse clutch drive plates before installing.





22. Install reverse clutch assembly on transmission case.
- Align teeth of high clutch drive plates before installing.

ADJUSTMENT 2





When any parts listed below are replaced, adjust total end play and reverse clutch end play.

TOTAL END PLAY





1. Adjust total end play "T1".





a. With original bearing race installed, place Tool onto oil pump. The long ends of legs should be placed firmly on machined surface of oil pump assembly. The gauging cylinder should rest on top of bearing race. Lock gauging cylinder in place with set screw.





b. Install gauging plunger into cylinder.
c. With needle bearing installed on high clutch drum, place Tool legs on machined surface of transmission case (with gasket). Then allow plunger to rest on needle bearing.





d. Measure gap between cylinder and plunger. This measurement should give exact total end play.

Total end play 'T1": 0.25 - 0.55 mm (0.0098 - 0.0217 inch)

- If end play is out of specification, decrease or increase thickness of bearing race as necessary.





Available bearing race: Refer to image.





2. Adjust reverse clutch drum end play "T2".





a. Place Tool on machined surface of transmission case (with gasket). Then allow gauging cylinder to rest on reverse clutch drum. Lock cylinder in place with set screw.
b. Install gauging plunger into cylinder.
c. With original thrust washer installed on oil pump, place Tool legs onto machined surface of oil pump assembly. Then allow plunger to rest on thrust washer.








d. Measure gap between cylinder and plunger with feeler gauge. This measurement should give exact reverse clutch drum end play.

Reverse clutch drum end play "T2": 0.55 - 0.90 mm (0.0217 - 0.0354 inch)

- If end play is out of specification, decrease or increase thickness of thrust washer as necessary.





Available thrust washer: Refer to image.