Oil Pump
OIL PUMP DISASSEMBLY AND REASSEMBLY
Disassembly Service Point
Drive Gear / Driven Gear Removal
1. Make reassembly alignment marks on the drive and driven gears.
Reassembly Service Points
>A< Oil Seal Installation
>B< Driven Gear / Drive Gear Side Clearance Measurement
Standard value: 0.03-0.05 mm (0.0012-0.0020 inch)
>C< Steel Ball Location
>D< Reaction Shaft Support Installation
1. Assemble the reaction shaft support and the pump housing, and tighten the five bolts by fingers.
2. Insert the special tool, Guide Pin MD998336, in the oil pump bolt hole and tighten the peripheries of the support and housing with the special tool, Band MD998335, to locate the support and housing.
3. Tighten the five bolts to the specified torque.
4. Make sure that the oil pump gear turns freely.
>E< O-Ring Installation
1. Install a new O-ring in the groove of the pump housing and apply petrolatum jelly to the O-ring.
FRONT CLUTCH DISASSEMBLY AND REASSEMBLY
Disassembly Service Point
Snap Ring Removal
1. Compress the return spring with the special tool.
2. Remove the snap ring.
Reassembly Service Points
>A< Snap Ring Installation
1. Compress the return spring with the special tool.
2. Install the snap ring.
>B< Clutch Plates/Clutch Discs Installation
1. Install all the clutch plates and discs as shown in then illustration.
2. Install all the clutch plates with their missing tooth portions (A in the illustration) in alignment.
3. Install the clutch reaction plate (No.1) and clutch pressure plate (No.5) with their shear droops directed as shown in the illustration.
4. If new clutch discs are to be used, soak them in ATF for more than 2 hours before assembling.
>C< Snap Ring Installation
1. Check clearance between the snap ring and clutch reaction plate. To check the clearance, hold the entire clutch reaction plate down with 50 Nm (11 lbs.) force. If clearance is out of standard value, select a snap ring to obtain the standard value.
Standard value: 0.8-1.0 mm (0.031-0.039 inch)
REAR CLUTCH DISASSEMBLY AND REASSEMBLY
Disassembly Service Point
Snap Ring Removal
1. Compress the return spring with the special tool.
2. Using a screwdriver, remove the snap ring.
Reassembly Service Points
>A< Snap Ring Installation
1. Compress clutch reaction plate with the special tool.
2. Install the snap ring so that the end gap may be positioned as illustrated.
>B< Clutch Pressure Plate / Clutch Plate / Clutch Reaction Plate Installation
1. Install all the clutch plates and discs as shown in the illustration.
2. Install the clutch pressure plate, clutch plates and clutch reaction plate with their missing tooth portions (A in the illustration) in alignment.
3. If new clutch discs are to be used, soak them in ATF for more than 2 hours before assembling.
>C< Snap Ring Installation
1. Check clearance between the snap ring and clutch reaction plate. To check the clearance, hold the entire clutch reaction plate down with 50 Nm (11 lbs.) force. If clearance is out of standard value, select a snap ring to obtain the standard value.
Standard value: 1.0-1.2 mm (0.039-0.047 inch)
>D< Input Shaft Installation
1. Install the input shaft with one of its oil groove aligned with the punch mark on the rear clutch retainer.
END CLUTCH DISASSEMBLY AND REASSEMBLY
Disassembly Service Point
End Clutch Piston Removal
1. Remove the piston. If it is hard to remove, place the retainer on the workbench with piston side down and blow air through the oil passage in the back of retainer.
Reassembly Service Points
>A< Snap Ring Installation
1. Using the special tool, fit the snap ring.
CAUTION: Make sure that the snap ring is flitted in position in the groove.
>B< Snap Ring Installation
1. Check clearance between the snap ring and clutch reaction plate. To check the clearance, hold the entire clutch reaction plate down with 50 Nm (11 lbs.) force. If clearance is out of standard value, select a snap ring to obtain the standard value.
Standard value: 0.60-0.85 mm (0.0236-0.0335 inch)
PLANETARY GEAR DISASSEMBLY AND REASSEMBLY
Disassembly Service Point
Rivet Removal
1. Install the stopper plate so that its tab does not cover the groove A in the one-way clutch outer race. If it does, turn the stopper plate in either direction until the notch A is completely visible.
2. Using a pin punch, drive out the rivet.
Reassembly Service Points
>A< One-Way Clutch Installation
1. Push the one-way clutch into the outer race. Make sure that arrow on the outside circumference of cage is directed upward as shown in the illustration when the one-way clutch is pushed in.
>B< Spring Washer Installation
1. Install the spring washer to the rivet so that it faces as shown in the illustration.
>C< Rivet Installation
1. Stake the rivet using a punch and press.
NOTE:
1. Use a punch with a 60° tip angle.
2. Stake the rivet with a load of 11,000-13,000 Nm (2,425-2,866 lbs.).
ANNULUS GEAR AND TRANSFER DRIVE GEAR SET DISASSEMBLY AND REASSEMBLY
Disassembly Service Point
Bearing / Transfer Drive Gear Removal
1. Using the special tool, remove the transfer drive gear together with two bearings from the output flange.
CAUTION: Install the special tool in position between the output flange and bearings.
2. Using the special tool, remove the bearings from both sides of the transfer drive gear.
Reassembly Service Points
>A< Transfer Drive Gear / Bearing Installation
1. Using the special tool, press-fit the bearings into both sides of the transfer drive gear.
2. Using the special tool, install the transfer drive gear to the output flange.
>B< Snap Ring Selection
1. Measure the snap ring groove clearance and select the appropriate spacer to obtain the specified end play.
Standard value: 0-0.09 mm (0-0.0035 inch)
DIFFERENTIAL DISASSEMBLY AND REASSEMBLY
Disassembly Service Points
Taper Roller Bearing Removal
CAUTION:
1. Do not reuse the bearing removed from the case.
2. Replace the inner and outer races of the taper rollers bearing as a set.
Lock Pin Removal
1. Using a pin punch, drive out the lock pin.
Reassembly Service Points
>A< Spacer / Side Gear Washer / Pinion / Pinion Shaft Installation
1. Fit the spacer to the back face of the side gear, then install the gear into the differential case.
2. Fit washer to back of pinion and rotate two pinions at the same time into position to mesh with the side gear.
3. Insert the pinion shaft.
4. Measure the backlash between the side gear and pinion.
Standard value: 0.025-0.150 mm (0.0010-0.0059 inch)
5. If the backlash is out of specification, select the appropriate spacer and disassemble and reassemble the gears as necessary.
NOTE: Adjust so that the backlash in both side gears equals.
>B< Lock Pin Installation
1. Align the lock pin hole in pinion shaft with that in the case and install the new lock pin.
CAUTION:
1. Do not reuse lock pin.
2. Make the lock pin lower than the surface of the differential case flange.
3. Press-fitting load is over 5,000 Nm (1,100 lbs.).
>C< Taper Roller Bearing Installation
1. Using the special tool, press-fit the bearings into both sides of the differential case.
>D< Bolts Installation
1. Apply ATF to the differential drive gear bolts, install and tighten with specified torque in the order shown in the figure.
Differential drive gear bolt: 135 Nm (98 ft. lbs.)
KICKDOWN SERVO DISASSEMBLY AND REASSEMBLY
LOW-REVERSE BRAKE DISASSEMBLY AND REASSEMBLY
SPEEDOMETER GEAR DISASSEMBLY AND REASSEMBLY
Reassembly Service Point
>A< Spring Pin Installation
1. Drive a new spring pin into the sleeve. Make sure that the slit in the spring pin does not face the gear.
VALVE BODY DISASSEMBLY AND REASSEMBLY
Reassembly Service Points
>A< Stopper Plate / N-D Plate / Teflon Ball / Steel Ball Location
1. Install the stopper plates, N-D plate, teflon ball, and steel balls into the upper valve body as shown.
>B< Upper Valve Body Sub Assembly Installation
1. Insert the special tool in the two guide pin holes in the upper valve body.
2. Install the upper separating plate and intermediate plate using the special tool as a guide, then tighten eight mounting bolts to the specified torque.
3. Remove the special tool.
>C< Oil Filter / Steel Ball / Relief Spring Installation
1. Install the oil filter, two steel balls, and spring to the intermediate plate.
>D< Lower Valve Body Assembly Installation
1. Insert the special tool to two guide holes of the intermediate plate.
2. Install the separating plate onto the valve body using the special tool as a guide.
3. Install the lower valve body assembly using the special tool as a guide, then tighten the mounting bolts to the specified torque.
4. Remove the special tool.
>E< Solenoid Valve Assembly Installation
1. Install the solenoid valves as shown.
TRANSFER SHAFT DISASSEMBLY AND REASSEMBLY
Disassembly Service Point
>A< Taper Roller Bearing Removal
Reassembly Service Points
>A< Taper Roller Bearing Installation
>B< Taper Roller Bearing Installation