Unit Disassembly And Assembly: Assembly
- As shown in the figure below, use a drift [22 mm (0.87 in) dia. commercial service tool] to drive manual shaft oil seals into the transmission case until it is flush.CAUTION:
- Never reuse manual shaft oil seals.
- Apply ATF to manual shaft oil seals.
- Install detent spring to transmission case. Tighten detent spring bolt to the specified torque.
: Bolt
- Install manual shaft to transmission case.
- Install parking rod (1) to manual plate (2).
- Install manual plate (with parking rod) to manual shaft.
- Install retaining pin (1) into the manual plate and manual shaft.
- Install retaining pin into the transmission case and manual shaft.
- Fit pinhole of the transmission case to pinhole of the manual shaft with a pin punch.
- Use a hammer to tap the retaining pin into the transmission case.CAUTION: Drive retaining pin to 5+/-1 mm (0.20+/-0.04 in) over the transmission case.
- Install D-rings to reverse brake piston.
- Install reverse brake piston to transmission case.
- Install needle bearing to drum support edge surface.CAUTION: Check the direction of needle bearing. Refer to Location of Needle Bearings and Bearing Races .
- Install seal rings to drum support.
- Install reverse brake spring retainer and reverse brake return spring to transmission case.
- Set the clutch spring compressor [SST: KV31102400 (J-34285 and J-34285-87)] (A) on reverse brake spring retainer and install snap ring (fixing spring retainer) (1) to transmission case while compressing return spring.CAUTION:
- Securely assemble them using a flat-bladed screwdriver so that snap ring tension is slightly weak.
- Be careful not to damage snap ring.
- Install reverse brake component part (drive plates, driven plates, and dish plates) to transmission case.
1
: Snap ring
2
: Retaining plate
3
: Drive plate (six pieces)
4
: Driven plate (six pieces)
5
: Dish plate
6
: Dish plate
CAUTION: Check order of plates. - Assemble N-spring.
- Install reverse brake retaining plate to transmission case.
- Install snap ring to transmission case.CAUTION: Be careful not to damage snap ring.
- Measure clearance between retaining plate and snap ring. If not within specified clearance, select proper retaining plate.
Specified clearance "A"
Standard: Refer to Reverse Brake Clearance .
Retaining plate: Refer to Reverse Brake Clearance
- Install needle bearing to transmission case.CAUTION: Check the direction of needle bearing. Refer to Location of Needle Bearings and Bearing Races .
- Install output speed sensor (1) to transmission case. Tighten output speed sensor bolt to the specified torque.
: Bolt
CAUTION:- Never subject it to impact by dropping or hitting it.
- Never disassemble.
- Never allow metal filings, etc. to get on the sensor's front edge magnetic area.
- Never place in an area affected by magnetism.
- As shown in the figure below, use the drift to drive rear oil seal into the rear extension (2WD) (A) or adapter case (AWD) (B) until it is flush.
1
: Drift [SST: 33400001 (J-26082)]
2
: Drift [Commercial service tool ?64 mm (2.52 in)]
CAUTION:- Never reuse rear oil seal.
- Apply ATF to rear oil seal.
- Install return spring (1) to parking pawl (2).
- Install parking pawl (with return spring) and pawl shaft to rear extension (2WD) or adapter case (AWD).
- Install parking actuator support to rear extension (2WD) or adapter case (AWD).
- Install needle bearing (1) to rear extension (2WD) or adapter case (AWD).CAUTION: Check the direction of needle bearing. Refer to Location of Needle Bearings and Bearing Races .
- Install rear extension assembly (2WD) or adapter case assembly (AWD) according to the following procedures.
- 2WD
- Install seal rings (1) to output shaft.
- Install parking gear (1) to output shaft (2).
- Install output shaft to transmission case.CAUTION: Be careful not to mistake front for rear because both sides looks similar. (Thinner end is front side.)
- Install bearing race to output shaft.
- Apply recommended sealant to rear extension assembly as shown in the figure, below.
*
: Genuine Anaerobic Liquid Gasket or equivalent. Refer to Recommended Chemical Products and Sealants .
Sealant starting point and end-point (A)
: Start and finish point shall be in the center of two bolts.
Overlap width of sealant starting point and end-point (B)
: 3 - 5 mm (0.12 - 0.20 in)
Sealant width (C)
: 1.0 - 2.0 mm (0.04 - 0.08 in)
Sealant height (C)
: 0.4 - 1.0 mm (0.016 - 0.04 in)
CAUTION: Completely remove all moisture, oil and old sealant, etc. from the transmission case and rear extension assembly mounting surfaces. - Install rear extension assembly to transmission case.CAUTION: Insert the tip of parking rod between the parking pawl and the parking actuator support when assembling the rear extension assembly.
- Tighten rear extension assembly bolts to the specified torque.
A
: Bolt
B
: Self-sealing bolt
- Install seal rings (1) to output shaft.
- AWD
- Install seal rings (1) to output shaft.
- Install parking gear (1) to output shaft (2).
- Install output shaft to transmission case.CAUTION: Be careful not to mistake front for rear because both sides looks similar. (Thinner end is front side.)
- Install bearing race to output shaft.
- Install gasket onto transmission case.CAUTION:
- Completely remove all moisture, oil and old gasket, etc. from the transmission case and adapter case assembly mounting surfaces.
- Never reuse gasket.
- Install adapter case assembly to transmission case.CAUTION: Insert the tip of parking rod between the parking pawl and the parking actuator support when assembling the adapter case assembly.
- Tighten adapter case assembly bolts to the specified torque.
1
: Bracket
A
: Bolt
B
: Self-sealing bolt
- Install seal rings (1) to output shaft.
- 2WD
- Install needle bearing to drum support.CAUTION: Check the direction of needle bearing. Refer to Location of Needle Bearings and Bearing Races .
- Install direct clutch assembly to reverse brake.CAUTION: Make sure that drum support edge surface and direct clutch inner boss edge surface come to almost same place.
- Install high and low reverse clutch assembly to direct clutch.
- Align the drive plate using a flat-bladed screwdriver.
- Install high and low reverse clutch hub, mid sun gear assembly, and rear sun gear assembly as a unit.CAUTION: Make sure that portion "A" of high and low reverse clutch drum protrudes approximately 2 mm (0.08 in) beyond portion "B" of rear sun gear.
- Install needle bearing to rear carrier assembly.CAUTION: Check the direction of needle bearing. Refer to Location of Needle Bearings and Bearing Races .
- Install bearing race to rear carrier assembly.CAUTION: Check the direction of needle bearing. Refer to Location of Needle Bearings and Bearing Races .
- Install rear carrier assembly to direct clutch drum.
- Install needle bearing (rear side) to mid carrier assembly.CAUTION: Check the direction of needle bearing. Refer to Location of Needle Bearings and Bearing Races .
- Install needle bearing (front side) to mid carrier assembly.CAUTION: Check the direction of needle bearing. Refer to Location of Needle Bearings and Bearing Races .
- Install mid carrier assembly to rear carrier assembly.
- Install seal rings (1) to input clutch assembly.
- Install needle bearing (1) to front carrier assembly.CAUTION: Check the direction of needle bearing. Refer to Location of Needle Bearings and Bearing Races .
- Install input clutch assembly (with front carrier assembly and rear internal gear) (1) to transmission case.CAUTION: Check that the needle bearing (2) is securely positioned. If the needle bearing position is misaligned, adjust it to the specified position.
- Install 1st one-way clutch (1) to front brake hub (with under drive carrier) (2).
- Check operation of 1st one-way clutch.
- Install under drive carrier (with 1st one-way clutch) (1) to transmission case.
- Install snap ring (1) to transmission case.CAUTION: Be careful not to damage snap ring.
- Install front brake component part (retaining plates, drive plates, and driven plate) to transmission case.
1
: Retaining plate (thin)
2
: Drive plate
3
: Driven plate
4
: Retaining plate (thick)
: Front
CAUTION: Check order of plates. - Install needle bearing (1) to under drive carrier assembly.CAUTION: Check the direction of needle bearing. Refer to Location of Needle Bearings and Bearing Races .
- Install under drive sun gear (1) to under drive carrier assembly.
- Adjustment of total end play "T".
- Measure clearance between bearing race (1) and oil pump cover (2).
- Select proper thickness of bearing race so that end play is within specifications.
- Measure dimensions "K" and "L", and calculate dimension "J".
1
: Transmission case
2
: Under drive sun gear
A
: Straightedge
"J"
: Distance between the oil pump fitting surface of transmission case and the needle bearing mating surface of under drive sun gear.
J = K - L
- Measure dimension "K" between the converter housing fitting surface of transmission case and the needle bearing mating surface of under drive sun gear.CAUTION:
- Never change the straightedge (A) installation position before the completion of "L" measurement.
- Measure dimension "K" in at least three places, and take the average.
- Measure dimension "L" between the converter housing fitting surface of transmission case and the oil pump fitting surface of transmission case.
1
: Transmission case
A
: Straightedge
CAUTION: Measure dimension "L" in at least three places, and take the average. - Measure dimension "K" and "L" in at least three places, and take the average.
- Calculate dimension "J".
J = K - L
- Measure dimension "K" between the converter housing fitting surface of transmission case and the needle bearing mating surface of under drive sun gear.
- Measure dimensions "M 1
" and "M 2
", and calculate dimension "M".
1
: Bearing race
2
: Needle bearing
3
: Oil pump assembly
A
: Straightedge
"M"
: Distance between the transmission case fitting surface of oil pump and the needle bearing on oil pump.
M = M 1 - M 2
- Place bearing race (1) and needle bearing (2) on oil pump assembly (3).
- Measure dimension "M 1
" between the transmission case fitting surface of oil pump and the end of oil pump.
1
: Bearing race
2
: Needle bearing
3
: Oil pump assembly
A
: Straightedge
CAUTION: Measure dimension "M 1 " in at least three places, and take the average. - Measure dimension "M 2
" between the needle bearing on oil pump and the end of oil pump.
1
: Bearing race
2
: Needle bearing
3
: Oil pump assembly
A
: Straightedge
CAUTION: Measure dimension "M 2 " in at least three places, and take the average. - Calculate dimension "M".
M = M 1 - M 2
- Place bearing race (1) and needle bearing (2) on oil pump assembly (3).
- Adjust total end play "T".
1
: Bearing race
2
: Oil pump assembly
T = J - M
Total end play "T"
: Refer to Total End Play .
- Select proper thickness of bearing race so that total end play is within specifications.
Bearing races
: Refer to Total End Play .
- Select proper thickness of bearing race so that total end play is within specifications.
- Adjustment of front brake clearance "C".
- Measure clearance between front brake piston (1) and front brake retaining plate (2).
- Select proper thickness of front brake retaining plat so that clearance is within specifications.
- Measure dimensions "O" and "P", and calculate dimension "N".
1
: Transmission case
2
: Front brake retaining plate
A
: Straightedge
"N"
: Distance between the oil pump fitting surface of transmission case and the front brake retaining plate.
N = O - P
- Measure dimension "O" between the converter housing fitting surface of transmission case (1) and the front brake retaining plate (2).CAUTION:
- Never change the straightedge (A) installation position before the completion of "P" measurement.
- Measure dimension "O" in at least three places, and take the average.
- Measure dimension "P" between the converter housing fitting surface of transmission case and the oil pump fitting surface of transmission case.
1
: Transmission case
A
: Straightedge
CAUTION: Measure dimension "P" in at least three places, and take the average. - Calculate dimension "N".
N = O - P
- Measure dimension "O" between the converter housing fitting surface of transmission case (1) and the front brake retaining plate (2).
- Measure dimensions "Q 1
" and "Q 2
", and calculate dimension "Q".
1
: Front brake piston
2
: Oil pump assembly
A
: Straightedge
"Q"
: Distance between the transmission case fitting surface of oil pump and the front brake piston.
Q = Q 1 - Q 2
- Measure dimension "Q 1
" between the transmission case fitting surface of oil pump and the straightedge on front brake piston.
1
: Front brake piston
2
: Oil pump assembly
A
: Straightedge
CAUTION: Measure dimension "Q 1 " in at least three places, and take the average. - Measure dimension "Q 2
" of the straightedge.
1
: Front brake piston
2
: Oil pump assembly
A
: Straightedge
- Calculate dimension "Q".
Q = Q 1 - Q 2
- Measure dimension "Q 1
" between the transmission case fitting surface of oil pump and the straightedge on front brake piston.
- Adjust front brake clearance "C".
1
: Front brake piston
2
: Front brake retaining plate
C = N - Q
Front brake clearance "C"
: Refer to Front Brake Clearance .
- Select proper thickness of retaining plate so that front brake clearance is within specifications.
Retaining plate
: Refer to Front Brake Clearance .
- Select proper thickness of retaining plate so that front brake clearance is within specifications.
- Remove under drive sun gear (1) from under drive carrier assembly.
- Install needle bearing (1) to under drive sun gear.CAUTION: Check the direction of needle bearing. Refer to Location of Needle Bearings and Bearing Races .
- Install O-ring (1) to oil pump assembly.
- Install seal ring (1) to oil pump assembly.
- Install bearing race (1) to oil pump assembly.
- Install under drive sun gear (with needle bearing) (1) to oil pump assembly (2).
- Install oil pump assembly (with under drive sun gear) to transmission case.CAUTION: Apply ATF to oil pump bearing.
- Apply recommended sealant to oil pump assembly as shown in the figure, below.
: Genuine RTV silicone sealant or equivalent. Refer to Recommended Chemical Products and Sealants .
CAUTION: Completely remove all moisture, oil and old sealant, etc. from the oil pump mounting bolts and oil pump mounting bolt mounting surfaces. - Tighten oil pump bolts (
) to the specified torque.
- Install O-ring to input clutch assembly.
- Install converter housing to transmission case, and tighten converter housing bolts (
) to the specified torque.
- Connect TCM connector (A) to joint connector.
- Install joint connector (1) to the control valve & TCM.CAUTION: Apply ATF to O-ring of joint connector.
- Install the control valve & TCM (1) to transmission case.CAUTION:
- Make sure that input speed sensor securely installs input speed sensor holes (A).
- Hang down output speed sensor harness toward outside so as not to disturb installation of the control valve & TCM.
- Adjust joint connector of the control valve & TCM to terminal hole of transmission case.
- Assemble it so that manual valve cutout is engaged with manual plate projection.
- Make sure that input speed sensor securely installs input speed sensor holes (A).
- Install bolts and clip (1) to the control valve & TCM. Tighten bolt (E) to the specified torque before tightening the other than bolts.
: Front
Bolt symbol
Length mm (in)
Number of bolts
A
43 (1.69)
3
B
40 (1.57)
2
C
54 (2.13)
6
D
50 (1.97)
2
E*
50 (1.97)
1
*: Reamer bolt
- Connect output speed sensor connector (A).
- Engage output speed sensor harness with terminal clips (
).
- Pull down joint connector (1).CAUTION: Be careful not to damage connector.
- Install snap ring (1) to joint connector (2).
- Install magnets (1) to oil pan.
- Install oil pan gasket to transmission case.CAUTION:
- Never reuse oil pan gasket.
- Install it in the direction to align hole positions.
- Completely remove all moisture, oil and old gasket, etc. from oil pan gasket mounting surface.
- Install oil pan (2) and clips (1) to transmission case.
: Front
: Oil pan mounting bolt
CAUTION:- Be careful not to pinch harnesses.
- Completely remove all moisture, oil and old gasket, etc. from oil pan mounting surface.
- Tighten oil pan mounting bolts to the specified torque in numerical order shown in the figure below, after temporarily tightening them. Tighten oil pan mounting bolts to the specified torque.
: Front
CAUTION: Never reuse oil pan mounting bolts. - Install drain plug to oil pan. Tighten drain plug to the specified torque.CAUTION: Never reuse drain plug gasket.
- Pour ATF into torque converter.
- Approximately 2 liter (2-1/8 US qt, 1-3/4 Imp qt) of ATF is required for a new torque converter.
- When reusing old torque converter, add the same amount of ATF as was drained.
- Install torque converter while aligning notches of torque converter with notches of oil pump.CAUTION: Install torque converter while rotating it.
- Measure dimension "A" to make sure that torque converter is in proper position.
B
: Scale
C
: Straightedge
Dimension "A"
: Refer to Torque Converter .