Part 1
REASSEMBLY
1. INSPECT ROTOR BUSH OF MG2 ASSEMBLY
Using a dial indicator, measure the inside diameter of the rotor bush.
Standard diameter: 20.025 - 20.046 mm (0.78838 - 0.78921 inch)
Maximum diameter: 20.096 mm (0.79118 inch)
If the inside diameter exceeds the limit, replace the MG2 assembly.
2. PLACE WOOD BLOCK UNDER MG1 ASSEMBLY TO STABILIZE
3. INSTALL DRAIN PLUG AND SCREW PLUG (MG1 side)
a. Apply liquid sealer to the screw plug and install it to the MG1 assembly with a hexagon wrench.
Sealant:
Part No. 08833-00080, TREE BOND 1344, LOCTITE 242 or equivalent
Torque: 12.7 Nm (130 kgf-cm, 9 ft. lbs.)
b. Install a new gasket and the drain plug.
Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)
4. PLACE WOOD BLOCK UNDER MG2 ASSEMBLY
NOTICE: Be careful not to bend the parking lock rod.
5. INSTALL FILLER PLUG AND SCREW PLUG (MG2 side)
a. Apply liquid sealer to the 2 screw plugs and install them to the MG2 assembly with a hexagon wrench.
Sealant:
A: Part No. 08833-00070, THREE BOND 1324 or equivalent
B: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
Torque: 24.5 Nm (250 kgf-cm, 18 ft. lbs.)
NOTICE: Be careful not to bend the parking lock rod.
b. Install 2 new gaskets and the 2 filler plugs.
Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)
6. INSTALL DIFFERENTIAL OIL SEAL RH (MG1 side)
a. Using SST and a hammer, install a new oil seal.
SST 09710-20011 (09710-06071), 09950-70010 (09951-07100)
Oil seal depth: 2.7 ± 0.5 mm (0.106 ± 0.020 inch)
b. Coat the lip of the oil seal with MP grease.
7. INSTALL DIFFERENTIAL OIL SEAL LH (MG2 side)
a. Using SST and a hammer, install a new oil seal LH.
SST 09710-20011 (09710-06071), 09950-70010 (09951-07100)
Oil seal depth: 2.7 ± 0.5 mm (0.106 ± 0.020 inch)
b. Coat the lip of the oil seal with MP grease.
8. INSTALL BREATHER PLUG
Torque: 11.3 Nm (111 kgf-cm, 8 ft. lbs.)
9. INSTALL OUTER RACE AND SHIM
HINT: If there is some deformation or scratch to the outer race and shim, replace each of them with a new one.
a. Place a wood block under the MG2 assembly to stabilize.
NOTICE:
- Set the MG2 assembly horizontally.
- Unreasonable force should not be applied o the high-voltage cable.
b. MG2 side:
Using SST and a hammer, install the outer race of differential side bearing LH and shim.
SST 09950-60020 (09951-00680), 09950-70010 (09951-07100)
HINT: If replacing the shim, install a new shim which has the same thickness with the removed.
c. MG2 side:
Using SST and a hammer, install the tapered roller bearing outer race LH of the counter driven gear and shim.
SST 09950-60020 (09951-00680), 09950-70010 (09951-07100)
HINT: If replacing the shim, install a new shim which has the same thickness as the one removed.
d. MG1 side:
Using SST and a hammer, install the side bearing outer race RH of the differential.
SST 09950-60020 (09951-00680), 09950-70010 (09951-07100)
e. MG1 side:
Using SST and a hammer, install the tapered roller bearing outer race RH of the counter driven gear.
SST 09950-60020 (09951-00680), 09950-70010 (09951-07100)
10. INSTALL DIFFERENTIAL TO MG2 ASSEMBLY
a. Install the differential assembly to the MG2 assembly.
HINT: Apply ATF to the side bearing.
b. Install the engine hanger onto the MG1 side as shown in the illustration, and lift it up by a chain device.
Engine hanger part No.:
12281-67070, S1228-11781
Bolt part No.:
91642-81045
91642-81265 2 pieces
Nut part No.:
90178-10001
90179-12147 2 pieces
c. Install the 13 bolts and MG1 assembly to the MG2 assembly.
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
d. Using SST, rotate the differential case assembly in both directions to make it fit.
SST 09564-32011
e. Using SST and a small torque wrench, measure the differential preload.
SST 09564-32011
Preload (Starting torque):
New bearing: 0.98 - 1.57 Nm (9.99 - 16.01 kgf-cm, 8.67 - 13.90 inch lbs.)
Reused bearing: 0.49 - 0.78 Nm (5.00 - 7.95 kgf-cm, 4.34 - 6.90 inch lbs.)
Preload (Turning torque): 0.78 - 1.37 Nm (60 rpm) (7.95 - 13.97 kgf-cm, 6.90 - 12.13 inch lbs.)
If the preload is not within the specified range, replace the shim of the differential outer race LH.
Shim thickness
11. INSTALL COUNTER DRIVEN GEAR TO MG2 ASSEMBLY
a. Remove the 13 bolts, separate the MG1 assembly and the MG2 assembly.
b. Install the counter driven gear to the MG2 assembly.
HINT: Apply ATF to the side bearing.
c. Install the engine hanger onto the MG1 side as shown in the illustration, and lift it up by a chain device.
Engine hanger part No.:
12281-67070, S1228-11781
Bolt part No.:
91642-81045
91642-81265 2 pieces
Nut part No.:
90178-10001
90179-121472 pieces
d. Install the MG1 assembly to the MG2 assembly with the 13 bolts.
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
e. Using SST, rotate the differential case assembly in both directions to make it fit.
SST 09564-32011
f. Using SST and a small torque wrench, measure the counter driven gear preload.
SST 09564-32011
Preload (Starting torque):
New bearing: 3.81 - 6.10 Nm (38.85 - 62.20 kgf-cm, 33.72 - 53.99 inch lbs.)
Reused bearing: 1.91 - 3.03 Nm (119.48 - 30.90 kgf - cm, 16.91 - 26.82 inch lbs.)
Preload (Turning torque): 3.29 - 6.66 Nm (60 rpm) (33.55 - 67.91 kgf-cm, 29.12 - 58.95 inch lbs.)
If the preload is not within the specified range, replace the shim of the counter driven gear LH.
Shim thickness
12. REMOVE 13 BOLTS, SEPARATE MG1 ASSEMBLY AND MG2 ASSEMBLY
13. ADJUST SHIM
a. Install the 2 bearing races and needle roller bearing to the MG1 assembly.
b. Install the drive sprocket assembly to the MG1 assembly.
c. Install the input shaft assembly.
d. Install the 2 bearing races and needle roller bearing.
e. Install the planetary ring gear.
f. Install the ring gear flange.
g. Using a straight edge and vernier calipers, measure the dimension "A" and "B" correctly.
h. Select a shim that will ensure that the value is within the specification.
Shim thickness
Dimension "B" - Dimension "A"
i. Install the counter drive gear assembly to the MG1 assembly.
j. Using a straight edge and vernier calipers, measure the dimension "A" and "B" correctly.
k. Select a shim thickness is surely within the specified range.
Shim thickness
Dimension "B" - Dimension "A"
14. INSTALL INPUT SHAFT ASSEMBLY TO MG2 ASSEMBLY
a. Install the shim selected in step 13 (h).
b. Install the ring gear flange.
c. Install the 2 races and thrust bearing.
HINT: Apply ATF to the thrust bearing.
d. Install the planetary ring gear.
e. Install the input shaft assembly.
15. INSTALL COUNTER DRIVE GEAR ASSEMBLY, CHAIN AND DRIVE SPROCKET ASSEMBLY
a. Install the shim selected in step 13 (k).
b. Install the counter drive gear assembly and chain at the same time.
NOTICE: Install the chain with the mark plate facing up.
c. Put the chain on the drive sprocket and install them.
HINT: Apply ATF to the drive sprocket needle roller bearing.
d. Install the 2 bearing races and needle roller bearing.
HINT: Apply ATF to the thrust bearing.