Part 1 of 2

DISASSEMBLY





1. Remove final gear.





2. Press out differential side bearings.





3. Remove speedometer drive gear.





4. Drive out pinion mate shaft retaining pin.





5. Draw out pinion mate shaft from differential case.
6. Remove pinion mate gears and side gears.

INSPECTION
Gear, washer, shaft and case





- Check mating surfaces of differential case, side gears, pinion mate gears and viscous coupling.
- Check washers for wear.

Bearings





- Make sure bearings roil freely and are free from noise, cracks, pitting or wear.
- When replacing taper roller bearing, replace outer and inner race as a set.

ASSEMBLY





1. Install side gear and thrust washers in differential case.
2. Install pinion mate gears and thrust washers in differential case while rotating them.
- Apply ATF to any parts.
3. Measure clearance between side gear and differential case with washers.





Clearance between side gear and differential case with washers: 0.1 - 0.2 mm (0.004 - 0.008 inch)





- If not within specification adjust clearance by changing thickness of side gear thrust washer.
Side gear thrust washers: Refer to Application and ID.





4. Install retaining pin.
- Make sure that retaining pin is flush with case.





5. Install speedometer drive gear on differential case.
- Align the projection of speedometer drive gear with the groove of differential case.





6. Install final gear and tighten fixing bolts in numerical order.





7. Press on differential side bearings.

Assembly 1





1. Install revolution sensor onto transmission case.
- Always use new sealing parts.











2. Install differential side oil seals on transmission case and converter housing, so that "A" and "B" are within specifications.





3. Install parking actuator support to transmission case.
- Pay attention to direction of parking actuator support.





4. Install parking pawl on transmission case and fix it with parking shaft.





5. Install return spring.

Adjustment 1
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. Tighten transmission case fixing bolts (A) and (B) to the specified torque.





5. Attach dial indicator on differential case at transmission case side.
6. Insert Tool into differential side gear from converter housing.
7. Move Tool up and down and measure dial indicator deflection.
Differential side bearing preload "T": 0.04 mm - 0.09 mm (0.0016 in. - 0,0035 in.)
8. Select proper thickness of differential side bearing adjusting shim(s) using SDS table as a guide.
Differential side bearing adjusting shim: Refer to Application and ID.





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 differential case and measure turning torque of final drive assembly.
- Turn final drive assembly in both directions several times to seat bearing rollers correctly.
Turning torque of final drive assembly (New bearing): 0.49 - 1.08 Nm (5.0 - 11.0 kg.cm, 4.3 - 9.5 inch lbs.)
- 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 PINION GEAR BEARING PRELOAD
1. Remove transmission case and final drive assembly from converter housing.
2. Select proper thickness of reduction pinion gear bearing adjusting shim using the following procedures.





a. Place reduction pinion 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 pinion gear.





- Measure dimension "B" between the end of reduction pinion 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 pinion gear and the adjusting shim mating surface of reduction pinion 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. Calculate "T" and select proper thickness of reduction pinion gear bearing adjusting shim using SDS table as a guide.
T = A - E
Reduction pinion gear bearing adjusting shim: Refer to Application and ID.





3. Install reduction pinion gear and reduction pinion 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 pinion 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 pinion gear.
- When measuring turning torque, turn reduction pinion gear in both directions several times to seat bearing rollers correctly.
Turning torque of reduction pinion gear: 0.11 - 0.69 Nm (1.1 - 7.0 kg.cm, 0.95 - 6.08 inch lbs.)

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 l2: 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 - 0.5 mm (0 - 0.020 inch)
Output shaft end play adjusting shim: Refer to Application and ID.
7. Install adjusting shim on output shaft bearing.





8. Apply locking sealant to transmission case as shown in illustration.
Locking sealant: Refer to Automatic Transmission/Transaxle; Service and Repair; Transaxle Overhaul; Major Overhaul.





9. Install side cover on transmission case.
- Apply locking sealant to the mating surface of transmission case.





10. Tighten side cover fixing bolts to specified torque.
- Do not mix bolts (A) and (B).
- Always replace bolts (A) as they are self-sealing bolts.