Part 1 of 2
Torque Converter Clutch Case Section1. Check the appearance of each component and clean.
CAUTION: Make sure each part is free of harmful cuts, damage and other faults.
2. Force-fit the oil seal to the torque converter clutch case with Service Tool ST.
ST 398437700 DRIFT
3. Install the differential assembly to the case, paying special attention not to damage the inside of the case (particularly, the differential side retainer contact surface).
4. 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: 0.3 - 0.5 mm (0.012 - 0.020 inch)
5. Wrap vinyl tape around the splined portion of the axle shaft.
6. Install the oil seal 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.
7. Using the ST, screw in the retainer until light contact is felt.
NOTE: Screw in the Right-Hand side slightly deeper than the Left-Hand side.
ST 499787000 WRENCH ASSY
8. Hypoid gear backlash adjustment and tooth contact check
1. Assemble the drive pinion assembly to the oil pump housing.
CAUTION:
^ Be careful not to bead the shims.
^ Be careful not to force the pinion against the housing bore.
2. Tighten four bolts to secure the roller bearing.
Tightening torque: 41 ± 3 Nm (4.2 ± 0.3 kg-m, 30.4 ± 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 ST1 and ST2.
ST1 498937100 HOLDER
ST2 499787700 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 ST1 and check to see if the backlash is within the standard value with ST2, ST3, ST4 and ST5.
NOTE: After confirming that the backlash is correct, check the tooth contact.
ST1 499787700 WRENCH
ST2 498247001 MAGNET BASE
ST3 498247100 DIAL GAUGE
ST4 499787500 ADAPTER WRENCH
ST5 498255400 PLATE
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.)
9. Install the seal pipe to the torque converter clutch case.
CAUTION: Be sure to use a new seal pipe.
10. Install two oil seals to the oil seal retainer with ST.
CAUTION:
^ Always discard old oil seals, and install new ones.
^ Pay attention to the orientation of the oil seals.
ST 499247300 INSTALLER
11. 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.
12. 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 ± 0.1 kg-m, 5.1 ± 0.7 ft. lbs.)
13. 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.
14. Install the rubber seal to the torque converter clutch case.
CAUTION: Be careful not to lose the rubber seal.
Transmission Case Section
1. Using a plastic hammer, force-fit the oil seal.
2. Install parking support to transmission case.
Tightening torque: 25 ± 2 Nm (2.5 ± 0.2 kg-m, 18.1 ± 1.4 ft. lbs.)
3. Install inhibitor switch to transmission case.
NOTE: Temporary tighten inhibitor switch.
4. Install detention spring to transmission case.
Tightening torque: 6 ± 1 Nm (0.6 ± 0.1 kg-m, 4.3 ± 0.7 ft. lbs.)
5. Insert range select lever, and tighten bolt.
Tightening torque: 6 ± 1 Nm (0.6 ± 0.1 kg-m, 4.3 ± 0.7 ft. lbs.)
6. Insert manual lever and parking rod.
7. Insert spring pin to manual lever.
8. Install the low and reverse piston.
CAUTION:
^ Be careful not to tilt the piston when installing.
^ Be careful not to damage the lip seal.
9. Install return spring.
10. Install retainer.
11. Install the one-way clutch inner race.
1. Using a press and Service Tool ST1, install the needle bearing to the inner race.
ST1 398497701 INSTALLER
NOTE: Use the following ST when removing.
2. Install two seal rings to one-way clutch inner race.
NOTE: Apply Vaseline to the groove of the inner race and to the seal ring after installation, so that the seal ring will not expand.
3. 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.
4. Install thrust needle bearing.
NOTE: Place transmission case with the front facing up.
12. Installation of the low & reverse brake:
1. Install dish plate, driven plates, drive plates, and a retaining plate, and secure with a snap ring.
NOTE: Pay attention to the orientation of the dish plate.
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 - 1.2 mm (0.028 - 0.047 inch)
Allowable limit: 2.2 mm (0.087 inch)
13. Install leaf spring of low and reverse brake
CAUTION: Pay attention to the direction and position of leaf spring during installation.
14. Install O-ring to 2-4 brake piston.
CAUTION:
^ If O-ring breaks or damage is noted, replace with new O-ring.
^ Apply a coat of Vaseline to inner side of O-ring before installation.
15. Install 2-4 brake piston to 2-4 brake piston retainer
16. Install 2-4 brake piston and retainer to transmission case
CAUTION: Align the hole in the 2-4 brake seal of transmission case with the hole in 2-4 brake piston retainer during installation.
17. Install 2-4 brake piston return spring to transmission case.
18. Position snap ring in transmission. Using ST, press the snap ring into place
ST 498677100 COMPRESSOR
19. Install planetary gear and low clutch assembly to transmission case.
Install carefully while rotating the low clutch and planetary gear assembly slowly paying special attention not to damage the seal ring.
20. Installation of the 2-4 brake:
1. Install pressure plate, drive plate, driven plate, retaining plate and snap ring.
2. Install 2-4 brake oil seal to transmission case.
CAUTION: Be sure to use a new one.
3. After all 2-4 brake component parts have been installed, blow in air intermittently and confirm the operation of the brake.
4. Measure the clearance between the retaining plate and the snap ring.
NOTE: Select a retaining plate with a suitable value from the following table, so that the clearance becomes the standard value.
Standard value: 0.8 - 1.2 mm (0.031 - 0.047 inch)
Allowable limit: 1.5 mm (0.059 inch)