Part 1
Part 1:
Part 2:
COMPONENTS
PREPARATION FOR DISASSEMBLY
1. REMOVE NEUTRAL START SWITCH
2. REMOVE SPEEDOMETER DRIVEN GEAR
3. REMOVE GOVERNOR BODY
4. REMOVE OIL PAN
5. REMOVE VALVE BODY
6. REMOVE TRANSAXLE REAR COVER OR OVERDRIVE CASE
Remove the eleven bolts and tap the transaxle rear cover or overdrive case with a plastic hammer to remove it
7. REMOVE INTERMEDIATE SHAFT
8. REMOVE PARKING LOCK PAWL BRACKET AND ROD
9. REMOVE PARKING LOCK PAWL
10. REMOVE MANUAL SHAFT AND LEVER
11. REMOVE GOVERNOR PRESSURE ADAPTOR
DISASSEMBLY OF DIFFERENTIAL
1. REMOVE CARRIER COVER
2. MEASURE TOTAL PRELOAD
Using a torque meter, measure the total preload, and make a note of it.
3. MEASURE BACKLASH OF SIDE GEAR
Measure each side gear backlash while holding one pinion toward the case.
Standard backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 in.)
4. REMOVE LH BEARING RETAINER
a. Remove the five bolts.
b. Tap the retainer with a plastic hammer to remove it.
c. Remove the O-ring from the retainer.
5. REMOVE RH SIDE BEARING CAP
Remove the two bolts and the side bearing cap.
6. REMOVE DIFFERENTIAL CASE, OUTER RACE AND ADJUSTING SHIM
Remove the differential case, the outer race and the adjusting shim from the case.
7. MEASURE DRIVE PINION PRELOAD
Using a torque meter, measure the drive pinion preload.
Preload (at starting):
Reused bearing: 5 - 8 kg-cm (4.3 - 6.9 in.-lb, 0.5 - 0.8 N.m)
The total preload measured in step 2 minus the drive pinion preload equals 1.5 - 2.0 kg-cm (1.3 - 1.7 in.-lb, 0.1 - 0.2 N.m).
If the result is not within this specification, the side bearing preload is bad.
REPLACEMENT OF DIFFERENTIAL
1. REPLACE SIDE BEARING
a. Fasten SST under the bearing above the cut-outs on the speedometer drive gear. Remove the bearing from the case.
SST 09502-10012
b. Using SST and a press, press the side bearing onto the differential case.
SST 09350-32013 (09351-32090, 09351-32120)
2. REPLACE RING GEAR
a. Loosen the staked part of the lock plate.
b. Remove the eight bolts and locking plates.
c. Using a copper hammer, tap on the ring gear to remove it from the case.
d. Clean the contact surface of the differential case.
e. Heat the ring gear to about 100 °C (212 °F) in an oil bath.
CAUTION: Do not heat the ring gear above 110 °C (230 °F).
f. Clean the contact surface of the ring gear with cleaning solvent.
g. Quickly install the ring gear on the differential case.
h. Install a new locking plates and set bolts. Tighten the set bolts uniformly and a little at a time. Torque the bolts.
Torque: 1,260 kg-cm (91 ft-lb, 124 N.m)
i. Using a hammer and drift punch. stake the locking plates.
NOTE: Stake one claw flush with the flat surface of the nut. For the claw contacting the protruding portion of the nut, stake only the half on the tightening side.
3. REPLACE LH OIL SEAL
a. Using a hammer and screwdriver, remove the oil seal.
b. Using SST, drive in a new oil seal.
SST 09350-32013 (09351-32130, 09351-32150)
Oil seal drive in depth: 0 mm (0 in.)
c. Coat the lip of oil seal with MP grease.
4. REPLACE RH OIL SEAL
a. Using a hammer and screwdriver, remove the oil seal.
b. Using SST, drive in a new oil seal until its surface is flush with the surface of the case.
SST 09350-32013 (09351-32130, 09351-32150)
c. Coat the lip of the oil seal with MP grease.
5. REPLACE LH SIDE BEARING OUTER RACE
a. Remove the oil seal.
b. Using SST, press out the outer race and shim.
SST 09350-32013 (09351-32090)
c. Place the shim onto the retainer.
NOTE: Use either the shim which was removed or one 2.10 mm (0.0827 in.) thick.
d. Using SST, press a new outer race into the retainer.
SST 09350-32013 (09351-32111, 09351-32130)
e. Install a new oil seal.
ADJUSTMENT OF DIFFERENTIAL CASE
1. CHECK SIDE GEAR BACKLASH
Measure the backlash of one side gear while holding one pinion toward the case.
Standard backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 in.)
2. DISASSEMBLE DIFFERENTIAL CASE
a. Drive out the pinion shaft lock pin from the side on which the ring gear is installed.
b. Remove the pinion shaft from the case.
c. Remove the two pinions and two side gears with the four thrust washers from each gear.
3. ASSEMBLE DIFFERENTIAL CASE
a. Install the removed thrust washers to the side gears.
b. Install the side gears with thrust washers, pinion thrust washers and pinion gears.
c. Install the pinion shaft.
d. Check the side gear backlash.
Measure the side gear backlash while holding one pinion gear toward the case.
Standard backlash: 0.05 - 0.20 mm (0.0020 - 0.0079 in.)
Refering to the table, select thrust washers which will ensure that the backlash is within specification. Try to select washers of the same size for both sides.
If the backlash is not within specification, install a thrust washer of a different thickness.
e. Install the lock pin.
1. Using a hammer and punch, drive the lock pin through the case and hole in the pinion shaft.
2. Stake the differential case.
DISASSEMBLY OF DRIVE PINION SHAFT
1. MEASURE DRIVE PINION PRELOAD
Using a torque meter, measure the preload of the drive pinion.
Preload:
Reused bearing 5 - 8 kg-cm (4.3 - 6.9 in.-lb, 0.5 - 0.8 N.m)
2. REMOVE DRIVE PINION CAP
3. REMOVE COUNTER DRIVEN GEAR
a. Using a chisel, loosen the staked part of the nut.
b. Install SST onto the gear.
SST 09350-32013 (09351-32031)
c. Using SST to hold the gear, remove the nut.
SST 09330-00021
d. Using SST, remove the gear and bearing.
SST 09350-32013 (09351-32061)
4. REMOVE OUTER RACE FROM CASE
Using SST, remove the outer race.
SST 09350-32013 (09308-10010)
5. REMOVE OIL SLINGER, SPACER AND GOVERNOR DRIVE GEAR OR ROTOR SENSOR
If the gear is too tight, remove it after removing the drive pinion.
6. REMOVE DRIVE PINION
a. Using SST, remove the snap ring.
SST 09350-32013 (09351-32050)
b. Insert a brass bar into the case hole to tap out the drive pinion.
c. Tap out the drive pinion and remove the bearing cage from the bore.
7. REMOVE GOVERNOR DRIVE GEAR OR ROTOR SENSOR
Using a shop press, press Out the governor drive gear or rotor sensor.
8. REMOVE BEARING CAGE FROM DRIVE PINION
9. REMOVE O-ring FROM BEARING CAGE
REPLACEMENT OF DRIVE PINION SHAFT COMPONENTS
1. REPLACE BEARING OF COUNTER DRIVEN GEAR
a. Using SST, press out the bearing.
SST 09950-00020
b. Using SST, press in a new bearing.
SST 09350-32013 (09351-32090)
2. REPLACE BEARING AND OUTER RACE OF DRIVE PINION SHAFT
a. Using SST, press out the bearing.
SST 09950-00020
b. Using SST, press in a new bearing.
SST 09350-32013 (09351-32100)
c. Using SST, drive out the outer race from the bearing cage.
SST 09350-32013 (09308-10010)
NOTE: Use SST without the bolt.
d. Using SST, press a new outer race into the bearing cage.
SST 09350-32013 (09351-32111, 09351-32130)
3. REPLACE OIL SEAL OF CAGE
a. Using SST, press out the two oil seals together.
SST 09350-32013 (09351-32090)
b. Using SST, press in a new oil seal facing the lip downward.
SST 09350-32013 (09351-32090)
Depth (Reference): 8 mm (0.31 in.)
c. Measure the oil seal press in depth.
Oil seal press in depth: 4 mm (0.16 in.)
d. Using SST, face the lip of the oil seal upward and press it in until its end is flush with the surface of the cage.
SST 09350-32013 (09351-32090)
e. Coat the lip of the oil seal with MP grease.
ADJUSTMENT OF DIFFERENTIAL SIDE BEARING PRELOAD
1. PLACE OUTER RACE AND ADJUSTING SHIM ONTO RH SIDE BEARING
Use the adjusting shim which was removed or one 2.40 mm (0.0945 in.) thick.
2. PLACE DIFFERENTIAL CASE INTO CASE
Be sure to install the adjusting shim.
3. INSTALL LH BEARING RETAINER
a. Do not install the O-ring yet.
b. Do not coat the bolt threads with sealer yet.
c. Temporarily tighten the five bolts evenly and gradually while turning the ring gear.
ty87terce_smat-108d.tif:
4. INSTALL RH SIDE BEARING CAP
Tighten the bolts evenly and gradually while turning the ring gear.
Torque: 500 kg-cm (36 ft-lb, 49 N.m)
5. TIGHTEN LH BEARING RETAINER
Torque: 195 kg-cm (14 ft-lb, 19 N.m)
6. ADJUST SIDE BEARING PRELOAD
Using SST and a torque meter, measure the preload of the ring gear.
SST 09564-32011
NOTE: Install SST on the pinion shaft.
Pre load (at starting):
New bearing 10 - 16 kg-cm (8.7 - 13.9 in-lb, 1.0 - 1.6 N.m)
Reused bearing 5 - 8 kg-cm (4.3 - 6.9 in.-lb, 0.5 - 0.8 N.m)
If the preload is not within specification, remove the ring gear from the case.
Reselect the RH adjusting shim.
NOTE: The preload will change about 3 - 4 kg-cm (2.6 - 3.5 in.-lb, 0.3 - 0.4 N.m) with each shim thickness.
7. REMOVE DIFFERENTIAL CASE AND COMPONENT PARTS
If the preload is adjusted within specification, remove the bearing retainer, differential case, RH side bearing and shim.
Be careful not to lose the adjusted shim.