Page 337 of 2389
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 six bolts.
(b) Tap the retainer with a plastic hammer to remove it
(c) Remove the O±ring from the retainer. 2. MEASURE TOTAL PRELOAD
Using a torque meter, measure the total preload, and
note the measurement value.
DISASSEMBLY OF DIFFERENTIAL
1. REMOVE CARRIER COVER(b) Remove the governor pressure adaptor from the
case.
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Page 338 of 2389
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.±Ib, 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 0.3 ± 1.7 in.±Ib,
0.1 ±0.2N±m).
If the result is not within this specification, the side bearing
preload is bad.
8. REMOVE DRIVE PINION CAP6. REMOVE DIFFERENTIAL CASE, OUTER RACE AND
ADJUSTING SHIM
Remove the differential case, the outer race and the
adjusting shim from the case.
9. REMOVE COUNTER DRIVEN GEAR
(a) Using a chisel, loosen the staked part of the nut. 5. REMOVE RH SIDE BEARING CAP
Remove the two bolts and the side bearing cap.
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Page 339 of 2389
(b) Install SST onto the gear.
SST 09350±32014 (09351±32031)
(c) Using SST to hold the gear, remove the nut.
SST 09330±00021
10. REMOVE OUTER RACE FROM CASE
Using SST, remove the outer race.
SST 09350±32014 (09308±10010)(d) Using SST, remove the gear and bearing.
SST 09350±32014 (09351±32061)
11. REMOVE OIL SLINGER
12. REMOVE SPACER
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Page 340 of 2389
(b) Insert a brass bar into case hole to tap out the
drive pinion.
(c) Tap the drive pinion and remove the bearing cage
from the bore. 14. REMOVE DRIVE PINION
(a) Using SST, remove the snap ring.'
SST 09350±32014 (09351±32050)
15. (A140L)
REMOVE GOVERNOR BODY DRIVE GEAR
Using a press, press out the governor body drive gear.
16. REMOVE BEARING CAGE FROM DRIVE PINION
17. REMOVE O±RING FROM BEARING CAGE13. (A140E)
REMOVE ROTOR SENSOR
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DISASSEMBLY OF DIRECT CLUTCH
1. CHECK PISTON STROKE OF DIRECT CLUTCH
(a) Install the direct clutch on the oil pump.
(b) Using a dial indicator (long type pick or SST),
measure the direct clutch piston stroke applying and
releasing the compressed air (4 ± 8 kg/cm2, 57 ±
114 psi, 392 ± 785 kPa) as shown.
SST 09350±32014 (09351±32190)
Piston stroke: 1.11 ± 1.44 mm (0.0437 ± 0.0567 in.)
If the piston stroke is greater than the maximum in-
spect the each component.
Direct Clutch
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Page 342 of 2389
5. REMOVE CLUTCH PISTON
(a) Install the direct clutch onto the oil pump.
(b) Apply compressed air to the oil pump to remove the
piston. (if the piston does not come out completely,
use needle±nose pliers to remove it.)
(c) Remove the direct clutch from the oil pump. 4. REMOVE PISTON RETURN SPRING
(a) Place SST on the spring retainer and compress the
springs with a shop press.
SST 09350±32014 (09351±32070)
(b) Remove the snap ring with the snap ring pliers. 2. REMOVE SNAP RING FROM CLUTCH DRUM
3. REMOVE FLANGE. DISCS AND PLATES
(d) Remove the two O±rings from the piston.(c) Remove the piston return spring.
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Page 343 of 2389

2. INSPECT DISCS, PLATES AND FLANGE
Check if the sliding surfaces of the discs, plates and
flange are worn or burnt. If necessary, replace them.
HINT:
wIf the lining of the disc is exfoliated or discolored, or
even a part of the printed numbers are defaced, re-
place all discs.
w Before assembling new discs, soak them in ATF for
at least two hours.
2. INSTALL PISTON RETURN SPRING
(a) Place the return spring and snap ring onto the piston
(b) Place SST on the spring retainer, and compress the return
spring with a shop press.
SST 09350±32014 (09351±32070)
(c) Install the snap ring with the snap ring pliers. Be surf the end
gap of snap ring is not aligned with the spring retainer
claw.
ASSEMBLY OF DIRECT CLUTCH
1. INSTALL CLUTCH PISTON IN DIRECT CLUTCH DRUM
(a) Install new O±rings to the piston. Coat the O±ring¿¿c
with ATF.
(b) Being careful not to damage the O±rings, press the
piston into the drum with the cup side up.
INSPECTION OF DIRECT CLUTCH
1. INSPECT CLUTCH PISTON
(a) Check that the check ball is free by shaking the piston.
(b) Check that the valve does not leak by applying low
pressure compressed air.
3. CHECK DIRECT CLUTCH BUSHING
Using a dial indicator, measure the inside diameter of
the direct clutch bushing.
Maximum inside diameter: 47.07 mm (1.8531 in.)
If the inside diameter is greater than the maximum, re-
place the direct clutch.
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Page 344 of 2389
5. RECHECK PISTON STROKE OF DIRECT CLUTCH
(a) Install the direct clutch on the oil pump.
(b) Using a dial indicator (long type pick or SST),
measure the direct clutch piston stroke applying and re-
leasing the compressed air (4 ± 8 kg/cm2, 57 ±
114 psi, 392 ± 785 kPa) as shown.
SST 09350±32014 (09351±32190)
Piston stroke: 1.11 ± 1.44 mm 10.0437 ± 0.0567 in.)
If the piston stroke nonstandard, select another flange.
HINT: There are two different flange thickness.
Flange thickness: 2.60 mm (0.1024 in.)
3.00 mm (0.1181 in.) 3. INSTALL PLATES, DISCS AND FLANGE
(a) Install plates and discs.
Install in order: P=Plate D=Disc
P±D±P±D±P±D
(b) Install the flange with the flat end facing downward.
4. INSTALL SNAP RING
Check that the end gap of the snap ring is not aligned
with one of the cutouts.
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