Assembly (1)
Assembly (1)
1. As shown below, use a drift (commercial service tool �22) to drive manual shaft oil seal into the transmission case until it is flush.
CAUTION:
^ Apply ATF to manual shaft oil seal.
^ Do not reuse manual shaft oil seal.
2. Install detent spring and spacer in transmission case.
3. Assemble manual shaft, manual plate, and parking rod after installing manual shaft to transmission case.
4. Install retaining pin into the manual plate and manual shaft.
a. Fit pinhole of the manual plate to pinhole of the manual shaft with a pin punch.
b. Use a hammer to tap the retaining pin into the manual plate.
CAUTION:
^ Drive retaining pin to 2mm ± 0.5 mm over the manual plate.
^ Do not reuse retaining pin.
5. Install retaining pin into the transmission case and manual shaft.
a. Fit pinhole of the transmission case to pinhole of the manual shaft with a pin punch.
b. Use a hammer to tap the retaining pin into the transmission case.
CAUTION:
^ Drive retaining pin to 5mm ± 1.0 mm over the transmission case.
^ Do not reuse retaining pin.
6. Install terminal cord assembly in transmission case.
CAUTION: Apply petroleum jelly to O-ring.
7. Install terminal cord assembly connectors in bracket.
8. Install O-rings in servo assembly.
CAUTION: Do not reuse O-rings. Apply petroleum jelly to O-rings.
9. Install return spring in servo assembly.
10. Install servo assembly in transmission case.
11. Using snap ring pliers, install snap ring in transmission case.
12. Install lip seal and D-ring in reverse brake piston.
CAUTION:
^ Do not reuse lip seal and D-ring.
^ Apply petroleum jelly to lip seal.
^ Apply ATF to D-ring.
13. Install reverse brake piston in transmission case.
14. Install seal rings in drum support.
CAUTION:
^ Do not reuse seal rings.
^ Apply petroleum jelly to seal rings.
15. Install needle bearing in transmission case.
CAUTION: Apply petroleum jelly to needle bearing.
16. After installing the return spring and spring retainer in transmission case, use a clutch spring compressor to install snap ring in transmission case.
CAUTION: Securely assemble them using a flat-bladed screwdriver so that snap ring tension is slightly weak.
17. Install reverse brake retaining plate, drive plate, driven plate and dish plate in transmission case.
18. Assemble N-spring.
19. Install snap ring in transmission case.
20. Measure clearance between retaining plate and snap ring. If not within specified clearance, select proper retaining plate.
Specified clearance "A":
Standard: 0.7 - 1.1 mm (0.028 - 0.043 inch)
Retaining plate: Refer to Specifications.
21. Install needle bearing in transmission case.
CAUTION: Apply petroleum jelly to needle bearing.
22. Install revolution sensor in transmission case.
23. As shown below, use a drift to drive rear oil seal into the extension until it is flush.
CAUTION:
^ Apply ATF to rear oil seal.
^ Do not reuse rear oil seal.
24. Install return spring in parking pawl.
25. Install parking pawl and pawl shaft in rear extension.
26. Install parking actuator support in rear extension.
27. Install seal rings in output shaft.
CAUTION:
^ Do not reuse seal rings.
^ Apply petroleum jelly to seal rings.
28. Install parking gear in output shaft.
29. Install output shaft in transmission case.
CAUTION: Be careful not to mistake front for rear because both sides looks similar. (Thinner end is front side.)
30. Install bearing race in output shaft.
31. Install needle bearing in output shaft.
CAUTION: Apply petroleum jelly to needle bearing.
32. Apply recommended sealant (Genuine Anaerobic Liquid Gasket or equivalent.) to rear extension assy as shown in illustration.
CAUTION: Complete remove all moisture, oil and old sealant, etc. From the transmission case and rear extension mounting surfaces.
33. Install rear extension assembly in transmission case.
34. Tighten rear extension assembly mounting bolts to specified torque. (Because terminal bracket is tightened together with output shaft & companion flange, it should be installed before procedure 33.)
CAUTION: Do not reuse self-sealing bolt.
Rear extension assy mounting bolt: 52 Nm (5.3 kgf-cm, 38 ft. lbs.)
Self-sealing bolt: 61 Nm (6.2 kgf-cm, 45 ft. lbs.)
35. Install direct clutch assembly in transmission case.
CAUTION: Make sure that drum support edge surface and direct clutch inner boss edge surface come to almost same place.
36. Install needle bearing in high and low reverse clutch drum.
CAUTION: Apply petroleum jelly to needle bearing.
37. Install high and low reverse clutch assembly in transmission case.
CAUTION: Be sure to replace high and low reverse clutch and mid sun gear as a set.
38. Using a flat-bladed screwdriver, range the drive plate.
39. Install high and low reverse clutch hub, mid sun gear assembly and rear sun gear assembly in transmission case.
CAUTION: Check that portion A of high and low reverse clutch drum protrudes approximately 2 mm (0.08 inch) beyond portion B of rear sun gear.
40. Install needle bearing in rear carrier assembly.
CAUTION: Apply petroleum jelly to needle bearing.
41. Install bearing race in rear carrier assembly.
CAUTION: Apply petroleum jelly to bearing race.
42. Install rear carrier assembly in transmission case.
43. Install needle bearing (rear side) in mid carrier assembly.
CAUTION: Apply petroleum jelly to needle bearing.
44. Install needle bearing (front side) in mid carrier assembly.
CAUTION: Apply petroleum jelly to needle bearing.
45. Install mid carrier assembly in transmission case.
46. Install front carrier assembly in transmission case. (With input clutch assembly and rear internal gear.)
47. Install seal rings in input clutch assembly.
CAUTION:
^ Do not reuse seal rings.
^ Apply petroleum jelly to seal rings.
48. Install band servo anchor end pin and lock nut in transmission case.
CAUTION: Do not reuse band servo anchor end pin.
49. Install brake band in transmission case.
CAUTION: Assemble it so that identification to avoid incorrect installation faces servo side.
50. Install front sun gear in transmission case.
CAUTION: Apply ATF to front sun gear bushing and one-way clutch end bearing.
51. Install needle bearing in front sun gear.
CAUTION: Apply petroleum jelly to needle bearing.
52. Adjust brake band tilting using clips so that brake band contacts front sun gear drum evenly.
53. Adjust brake band.
a. Loosen lock nut.
b. Tighten band servo anchor end pin to specified torque.
: 5.0 Nm (0.51 kgf-cm, 44 inch lbs.)
c. Back of band servo anchor end pin three turns.
d. While band servo anchor end pin, tighten lock nut to specified torque.