Part 2

3. Extract the axle shaft with SST1 and SST2.

CAUTION: Do not reuse the circlip.

SST1 499095500 REMOVER
SST2 499247300 INSTALLER





4. Remove the differential case assembly.

CAUTION:
- Remove the seal pipe if it is attached. (Reusing is not allowed.)
- Be careful not to damage the retainer mounting hole of the torque converter clutch case and the speedometer gears.





5. Remove the snap ring. Then remove the speedometer driven gear.
6. Remove vehicle speed sensor 2.





7. Tap out the speedometer shaft to the outside of the case, and remove the oil seal.

6. Extension Section





1. Take out the transfer clutch by lightly tapping the end of the rear drive shaft.

CAUTION: Be careful not to damage the oil seal in the extension.





2. Remove duty solenoid C, transfer valve body and the transfer pipe.

CAUTION:
- Take out the inlet filter.
- Do not damage the O-ring.
- Be careful not to bend the pipe.





3. Take out the roller bearing inner race with SST.

SST 398527700 PULLER

4. Take out the roller bearing outer race with SST.

NOTE: Hook SST in the inner side of the roller bearing outer race.

SST 398527700 PULLER


C: ASSEMBLY OF OVERALL TRANSMISSION
1. Torque Converter Clutch Case Section
1. Check the appearance of each component and clean.

CAUTION: Make sure each part is free of harmful cuts, damage and other faults.





2. Install the washer and snap ring to the speedometer shaft with SST, and set the oil seal. Then force-fit the shaft to the torque converter clutch case.
SST 499827000 PRESS
3. Install vehicle speed sensor 2.

CAUTION: Use new vehicle speed sensor 2, if it has been removed.

Tightening torque:
5.9 ± 1.5 Nm (60 ± 15 kg-cm, 52 ± 13 inch lbs.)





4. Install the speedometer driven gear to the speedometer shaft, and secure with a snap ring.





5. Force-fit the oil seal to the torque converter clutch case with SST.
SST 398437700 DRIFT





6. Install the differential assembly to the case, paying special attention not to damage the speedometer gears (drive and driven) and the inside of the case (particularly, the differential side retainer contact surface).
7. Install the circlip to the axle shaft, insert the shaft into the differential assembly, and tap it into position with a plastic hammer.

CAUTION:
- If no play is felt, check whether the shaft is fully inserted. If shaft insertion is correct, replace the axle shaft.
- Be sure to use a new circlip.

Thrust play:
Approx. 0.3 - 0.5 mm (0.012- 0.O2O inch)





8. Wrap vinyl tape around the splined portion of the axle shaft.
9. Install the oil sea[ and outer race (taper roller bearing) to the differential side retainer. Then screw in the retainer and the O-ring after coating the threads with oil.

CAUTION:
- Pay attention not to damage the oil seal lips.
- Do not confuse the right-hand and left-hand oil seals.
- Keep the O-ring removed from the retainer.





10. Using the SST, screw in the retainer until light contact is felt.

NOTE:
Screw in the right-hand side slightly deeper than the left-hand side.

SST 499787000 WRENCH ASSY
11. Hypoid gear backlash adjustment and tooth contact check





1. Assemble the drive pinion assembly to the oil pump housing.

CAUTION:
- Be careful not to bend the shims.
- Be careful not to force the pinion against the housing bore.





2. Tighten four bolts to secure the roller bearing.

Tightening torque:
39 ± 3 Nm (4.0 ± 0.3 kg-m, 28.9 ± 2.2 ft. lbs.)





3. Install the oil pump housing assembly to the torque converter clutch case, and secure evenly by tightening four bolts.

CAUTION:
- Thoroughly remove the liquid gasket from the case mating surface beforehand.
- Use an old gasket or an aluminum washer so as not to damage the mating surface of the housing.

Tightening torque:
41 ± 3 Nm (4.2 ± 0.3 kg-m, 30.4 ± 2.2 ft. lbs.)





4. Rotate the drive pinion several times with SST1 and SST2.
SST1 498937100 HOLDER
SST2 499787100 WRENCH





5. Tighten the left-hand retainer until contact is felt while rotating the shaft. Then loosen the right-hand retainer. Keep tightening the left-hand retainer and loosening the right-hand retainer until the pinion shaft can no longer be turned.. This is the "zero" state.





6. After the "zero" state is established, back off the left-hand retainer 3 notches and secure it with the lock plate. Then back off the right-hand retainer and retighten until it stops. Repeat this procedure several times. Tighten the right-hand retainer 1-3/4 notches further. This sets the preload. Finally, secure the retainer with its lock plate.





NOTE:
Turning the retainer by one tooth changes the backlash about 0.05 mm (0.0020 inch).





7. Turn the drive pinion several rotations with SST1 and check to see if the backlash is within the standard value with SST2, SST3 and SST4.

NOTE:
After confirming that the backlash is correct, check the tooth contact.

SST1 499787100 WRENCH
SST2 498247001 MAGNET BASE
SST3 498247100 DIAL GAUGE
SST4 499757800 ADAPTER WRENCH

Backlash:
0.13 - 0.18 mm (0.0051 - 0.0071 inch)





8. Apply red lead evenly to the surfaces of three or four teeth of the crown gear. Rotate the drive pinion in the forward and reverse directions several times. Then remove the oil pump housing, and check the tooth contact pattern. If tooth contact is improper, readjust the backlash or shim thickness.





9. If tooth contact is correct, mark the retainer position and loosen it. After fitting the O-ring, screw in the retainer to the marked position. Then tighten the lock plate to the specified torque.

Tightening torque:
25 ± 2 Nm (2.5 ± 0.2 kg-m, 18.1 ± 1.4 ft. lbs.)





12. Install the seal pipe to the torque converter clutch case.





13. Install two oil seals to the oil seal retainer with SST.

CAUTION:
- Always discard old oil seals, and install new ones.
- Pay attention to the orientation of the oil seals.

SST 499247300 INSTALLER





14. Attach the O-ring to the oil seal retainer with vaseline. Install the seal to the oil pump housing bore.

CAUTION: Always discard old O-rings and install new ones.





15. Install the oil seal retainer taking care not to damage the oil seal lips. Then secure with three bolts.

NOTE: Make sure the O-ring is fitted correctly in position.

Tightening torque:
7 ±1 Nm (0.7 ± 0.l kg-m, 5.1 ± 0.7 ft. lbs.)





16. Apply vaseline to the groove on the oil pump cover, and install two (R) seal rings and two (H) seal rings.

NOTE:
- Fit the seal ring after compressing, and rub vaseline into the seal ring to avoid expansion.
- The "R" seal ring has a large diameter, while "H" has small diameter.





17. Install the rubber seal to the torque converter clutch case.

CAUTION: Be careful not to lose the rubber seal.


2. Transmission Case Section





1. Press-fit the roller bearing to the transmission case with SST.
SST 398487700 DRIFT





2. Using a plastic hammer, force-fit the oil seal.





3. Install the manual plate and shaft, and secure with a spring pin.

CAUTION: Be careful not to damage the oil seal lip.

NOTE: After installation, make sure of smooth movement.





4. Assemble the manual lever and parking rod to the inside shaft, and secure with a nut.

Tightening torque:
47 ± 2 Nm (4.8 ± 0.2 kg-m, 34.7 ± 1.4 ft. lbs.)

5. Installation of inhibitor switch
1. Install the inhibitor switch to the transmission case. Fit the projecting portion of the switch in the recessed portion of the case, and tighten three bolts temporarily.





2. Insert the range select lever into the shaft, and tighten the nut.

Tightening torque:
47 ± 5 Nm (4.8 ± 0.5 kg-m, 34.7 ± 3.6 ft. lbs.)





6. Install the detention spring.

NOTE: Position the spring so that its center is aligned with the center of the manual plate.

Tightening torque.
6 ± 1 Nm (0.6 ± 0.1 kg-m, 4.3 ± 0.7 ft. lbs.)





7. Install the lathe cut seal rings to the I.D./O.D. of the low and reverse piston. Then install the piston into the case with a press, SST1 and SST2.

CAUTION:
- Be careful not to tilt the piston when installing.
- Be careful not to damage the lip seal.

SST1 398673600 COMPRESSOR
SST2 498627000 SEAT





8. Install the one-way clutch inner race.
1. Using a press and SST1, install the needle bearing to the inner race.

SST1 398497701 INSTALLER

NOTE: Use the following SST when removing.

SST 398527700 PULLER ASSY





2. Install four seal rings and thrust washer.

NOTE:
- Apply vaseline to the groove of the inner race and to the seal ring after installation, so that the sealing will not expand.
- Align the cutout portion of the thrust washer with the inner race pin.





3. Place the spring retainer on the inner race. Install the spring to the recessed portion of the piston. Then tighten eight socket head bolts from the rear side of the transmission case.

Tightening torque.
25 ± 2 Nm (2.5 -+ 0.2 kg-m, 18.1 ± 1.4 ft. lbs.)

CAUTION: Be sure to tighten evenly.

9. Install the band servo sub assembly.





10. Press the O.D. servo retainer into position with SST1 and SST2, and secure with a snap ring.
SST1 498677010 COMPRESSOR
SST2 399703600 PULLER ASSY

CAUTION: Perform the following operations with the transmission case set vertically on wooden blocks.

11. Measure thickness of each drive plate.

Standard value:
1.8 mm (0.071 inch)

Wear limit.
1.6 mm (0.063 inch)

12. Installation of the low & reverse brake:





1. Install wave spring, driven plates, drive plates, and a retaining plate, and secure with a snap ring.

NOTE: Pay attention to the orientation of the wave spring.





2. Apply compressed air intermittently to check for operation.








3. Check the clearance. (Selection of retaining plate)

NOTE: Before measuring clearance, place the same thickness of shim on both sides to prevent retaining plate from tilting.

Standard value:
0.7 - 1.0 mm, (0.028 - 0.039 inch)
Allowable limit:
Except OUTBACK,
2.0 mm (0.079 inch)
OUTBACK:
2.2 mm (0.087 inch)

13. Install the forward clutch drum.
1. Install carefully while rotating the forward clutch drum slowly paying special attention not to damage the seal ring.





2. Installation is completed when the forward clutch drum recedes 2.5 mm (0.098 inch) from the inner race surface.





14. Assemble the overrunning clutch hub.

CAUTION: Install thrust needle bearing in the correct direction.

NOTE:
- Join the thrust needle bearing and thrust washer with vaseline, and then install them together.
- Make sure that the splines are engaged correctly.





15. Install the one-way clutch outer race.

NOTE: Make sure the forward clutch splines are engaged correctly.

16. Assemble the rear internal gear.
1. Join the thrust needle bearing and thrust washer to the internal gear with vaseline, and install the internal gear while rotating it.
2. Securely engage the bearing with the dog of the overrunning clutch hub.

CAUTION:
Install thrust needle bearing in the correct direction.





NOTE:
Installation is complete when the snap ring top surface of the forward clutch drum recedes approximately 3.5 mm (0.138 inch).





17. Install the rear planetary carrier.
Attach the thrust needle bearing to the inside of the carrier with vaseline. Then install the carrier while rotating slowly.

CAUTION:
Install thrust needle bearing in the correct direction.