Fluid Pump: Service and Repair

NOTE: The content of this article/image reflects the changes called out by TSB 18-88-05.

Oil Pump

REMOVAL
1) Remove the transmission assembly from the vehicle.
2) Extract the torque converter clutch assembly.





3) Remove the input shaft.
4) Lift-up lever behind the transmission harness connector and disconnect it from stay.
5) Disconnect inhibitor switch connector from stay.
6) Disconnect the air breather hose.
7) Remove the oil charger pipe.
8) Remove the oil cooler inlet and outlet pipes.
9) Separate torque converter clutch case and transmission case sections.
10) Separate transmission case and extension case sections.
11) Remove the reduction drive gear. (MPT model)
12) Remove the center differential carrier. (VTD model)
13) Remove the reduction driven gear.





14) Loosen the oil pump housing mounting bolts.





15) Place two wooden blocks on the workbench, and stand the transmission case with its rear end facing down.

NOTE:
^ Be careful not to scratch the rear mating surface of the transmission case.
^ Note that the parking rod and drive pinion protrude trip from the mating surface.





16) Remove the oil pump housing and adjusting thrust washer.





17) Remove the oil seal retainer. Also remove the O-ring and oil seal (air breather).
18) Remove O-rings from oil pump housing.
19) Remove the drive pinion assembly.

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

NOTE:
^ 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: 40 Nm (4.1 kgf-m, 30 ft. lbs.)





3) While paying attention to the orientation of the oil seals, install two new oil seals to the oil seal retainer using ST.
ST 499247300 INSTALLER





4) Attach the new O-ring to the oil seal retainer with petrolatum. Install the seal to the oil pump housing bore.





5) Install the oil seal retainer taking care not to damage the oil seal lips. Then secure with three bolts.
Tightening torque: 7 Nm (0.7 kgf-m, 5.1 ft. lbs.)
6) Make sure the O-ring is fitted correctly in position.
7) Secure the housing with two nuts and the bolt.
Tightening torque: 42 Nm (4.3 kgf-m, 31 ft. lbs.)





8) Install the torque converter clutch case assembly to the transmission case assembly.
9) Install reduction driven gear.
10) Install reduction drive gear. (MPT model)
11) Install the center differential carrier. (VTD model)
12) Combine the extension case with the transmission case, and install vehicle speed sensor 1 (rear).





13) Insert inhibitor switch and transmission connector into stay.
14) Install air breather hose.
15) Install the oil cooler pipes.
16) Install the oil charger pipe with O-ring.





17) Insert the input shaft while turning lightly by hand. At this time, not to damage the bushing.
Normal protrusion A: 50 - 55 mm (1.97 - 2.17inch)
18) Install the torque converter clutch assembly.
19) Install the transmission assembly to the vehicle.

DISASSEMBLY





1) Remove four seal rings.





2) Lightly tap the end of the stator shaft to remove the cover.





3) Remove the inner and outer rotor.

ASSEMBLY





1) Install oil pump rotor assembly to oil pump housing.





2) Align both pivots with the pivot holes of the cover, and install the oil pump cover being careful not to apply undue force to the pivots.
Tightening torque: 25 Nm (25 kgf-m, 18.1 ft. lbs.)
3) After assembling, turn the oil pump shaft to check for smooth rotation of the rotor.





4) Install the oil seal retainer and new seal rings. After installation, adjust the drive pinion backlash and tooth contact.

INSPECTION
1) Check seal ring and oil seal for breaks or damage.
2) Check other parts for dents or abnormalities.





3) Selection of oil pump rotor assembly

1) Tip clearance
Install inner rotor and outer rotor to oil pump. With rotor gears facing each other, measure crest-to-crest clearance.
Tip clearance: 0.02 - 0.15 mm (0.0008 - 0.0059 inch)





2) Side clearance
Set a depth gauge to oil pump housing, then measure oil pump housing-to-rotor clearances.
Side clearance: 0.02 - 0.04 mm (0.0008 - 0.0016 inch)





3) If depth and/or side clearances are outside specifications, replace rotor assembly.

^ Measure the total end play and adjust to within specifications.

ADJUSTMENT





1) Using the ST, measure the distance from the end surface of ST to the recessed portion "L" of the high clutch drum.
ST 398643600 GAUGE





2) Using the ST, measure the distance from the oil pump housing mating surface to the end surface of ST.
ST 398643600 GAUGE











3) Calculation of total end play
Select suitable bearing race from among those listed in this table so that clearance C is in the 0.25 to 0.55 mm (0.0098 to 0.0217 inch) range.
C = (L + G) - a

4) After completing end play adjustment, insert the bearing race in the recess of the high clutch. Attach the thrust needle bearing to the oil pump cover with petrolatum.
5) After correctly installing the new gasket to the case mating surface, carefully install the oil pump assembly. Be careful to avoid hitting the drive pinion against the inside of the case.
6) Install both parts with dowel pins aligned. Make sure no clearance exists at the mating surface.