Page 708 of 1395
Valve Body
Repair
NOTE: This repair is only necessary if one or more ofthe valves in a valve body do not slide smoothly in theirbores. Use this procedure to free the varves.
'1. Soak a sheet of #600 abrasive paper in ATF forabout 30 minutes.
2. Carelully tap the valve body so the sticking valvedrops out of its bore. lt may be necessary to use asmall screwdriver to pry the valve free. Be carefulnot to scratch the bore with the screwdriver.
4.
Inspect the valve for any scutf marks. Use the ATF-soaked #600 paper to polish off any burrs that areon the valve, then wash the valve in solvent and dryit with compressed air.
Roll up half a sheet of ATF-soaked #600 paper andinsert it in the valve bore of the sticking valve.Twist the paper slightly, so that it unrolls and fitsthe bore tightly, then polish the bore by twisting thepaper as you push it in and out.
NOTE: The valve body is aluminum and doesn,trequire much polishing to remove any ourrs.
,l
14-192
5.Remove the #600 paper. Thoroughly wash theentire valve body in solvent, then dry it with com-pressed ar.
Coat the valve with ATF, then drop it into its bore, ltshould drop to the bottom of the bore under its ownweight. lf not, repeat step 4, then retest. lf the valvestill sticks, replace the valve body.
Remove the valve. and thoroughly clean it and thevalve body with solvent. DrV all parts with com-pressed air, then reassemble using ATF as a lubricant.
1.
w
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Page 728 of 1395
Sub-shaft Bearings
Replacement
NOTE: Lubricate all parts with ATF before reassembly.
1. Expand the snap ring with snap ring pliers. thenpush the bearing out of the transmission housing
using the special tools and a press as shown.
Remove the needle bearing stop.
Remove the needle bearing from the transmission
housing using a drift.
ATTACHMENT,ai:l x 68 mm07746 - 00105q)
14-212
SNAP RING
4. Install a new needle bearing in the housing using
the sOecial tools and a oress as shown.
7.
cI
32x35mm077/46 - qt10t(x,
Expand the snap ring with snap ring pliers, then
insert the ball bearing part-way into the housing
using the special tools and a press as described in
step 1. Install the bearing with the groove facing
outside the housing.
Release the pliers, then push the bearing down into
the housing until the snap ring snaps in place
around it.
After installing the ball bearing verify the fottowing:
. The snap ring is seated in the bearing and hous-
Ing grooves.
. The ring end gap is correct.
ENDGAP:0-7mml0 - 0.28 inl
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Page 757 of 1395
Transfer Gear Bscklash Inspection and Transfer Gear
Tooth Contact Inspection
2. Install the 35 mm thrust shim on the transfer driven
gear shaft, then install the tapered roller bearing
using the special tools and a press.
DRIVER {0 mm LD.077146 - 0030100
TRANSFER DRTVEN ;;.GEAR SHAFT u, 745 - 0O304O0
Place the tapered roller bearing on the bearing outer
race of the companion flange side of the transfer
housrng.
Install the new oil seal on the transfer housing
using the special tools.
OIL SEAL DRIVERATTACHMENT07JAD - PH80101
5. Install the transfer driven gear shaft in the transfer
housing. Do not install the transfer spacer on the
transfer driven gear shaft in this step.
Install the companion flange, conical spring washer,
and locknut on the transfer driven gear shaft. Do
not install the O-ring and the back-up ring on the
transfer gear shaft in this step.
6.
COMPANIONFLANGE
{cont'd)
TRANSFER
TRANSFER HOUSING
14-241
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Page 758 of 1395
Transfer Assembly
Reassembly (cont'd)
7.Secure the transfer housing in a bench vise with
soft jaws, then install the special tool on the com-
panion flange. To prevent damage to the transfer
housing, always use soft jaws or equivalent materi-
als between the transfer housing and the vise.
Tighten the locknut while measuring the starting
torque so the starting torque is within 0.98 - '1.39
N.m (10.0 - 14.2 kgf.cm, 8.68 - 12.3 lbnin).
NOTE:
Coat the threads of the locknut, and the shaft
with ATF before installing the locknut.
Do not stake the locknut in this step.
STARTING TOROUE:
0.98 - 1.39 N.m
{10.0 - 14.2 kgrf.cm,8.68 - 12.3 lbf'inl
COMPANION FLANGEHOLDER
07JAB - @1020A
14-242
9. Install the transfer shaft in the transfer housing,
then install the tapered roller bearing, transfer shaft
collar.25 mm thrust shim, transfer drive gear, coni-
cal spring washer, and locknut on the transfer shaft.
NOTE:
. Coat the threads of the locknut. and the shaft
with ATF before installing the locknut.
. Do not stake the locknut in this step.
TRANSFER
THRUST SXIM,25 mmSelective pan
TRANSFER DRIVEGEAR
CONICAL SPRINGWASHERReplace.
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Page 759 of 1395
10.
11.
Put a 14 mm Allen wrench in the gear side of the
transfer shaft, then secure the Allen wrench in a
bench vise.
Tighten the transfer shaft locknut.
NOTE:
. The transfer shaft locknut has left-hand threads.
. Do not stake the locknut in this step.
TOROUE: 118 N'm 112.0 kgf.m, 87 lbf.ftl
Temporarily install the transfer cover A without
O-ring.
TRANSFER HOUSING
TRANSFER COVER A
the12.
g/FrE24 N.m 12.4 kgt.m, 17 lbf.ftl
TOROUE WRENCH
tt el
g 9-r'r.ru--g 24 N.m 12.4 |
14-243
13.
14.
Rotate the companion flange several times to seat
the tapered roller bearing.
Set a dial indicator on the companion flange, then
measure the transfer gear backlash.
STANDARD: 0.06 - 0.16 mm {0.02 - 0.06 inl
COMPANION FLANGE
lf the measurement is not within the standard.
remove the transfer shaft locknut and replace the 25
mm thrust shim. Select and install a new 25 mm
thrust shim. then recheck the measurement. Do not
use more than two 25 mm thrust shims to adiust
the transfer gear backlash.
THRUST SHIM, 25 mm
(cont'd)
15.
DIAL INOICATOR
Shim No.Part NumborThickness
I29411-P1C-0001.70 mm (0.067 in)
229412-P1C-0001.73 mm (0.068 in)
29413-P1C-0001.76 mm (0.069 in)
429414-P1C-0001.79 mm (0.070 in)
29415-PlC-0001.82 mm (0.072 in)
629416-P1C-0001.85 mm (0.073 ini
729417-PlC-0001.88 mm (0.074 in)
d29418-P1C-0001.91 mm {0.075 in)
29419-P1C-0001.94 mm (0.076 in)
1029420-PtC-0001.97 mm (0.078 in)
1129421 - P1C - 0002.00 mm (0.079 in)
29422-P1C-0002.03 mm 10.080 in)
29423-P'1C-0002.06 mm (0.081 in)
1429424-P1C-0002.09 mm 10.082 in)
29425-P1C-0002.12 mm (0.083 in)
1629426-P1C-0002.'15 mm (0.085 in)
1729427 - P1C -O002.18 mm (0.086 in)
1829428-PlC-0002.21 mm (0.087 in)
1929429-P1C-0002.24 mm {0.088 in)
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Page 763 of 1395
30. Put a 14 mm Allen wrench in the gear side of the
transfer shaft. then secure the Allen wrench in a
bench vise. Tighten the transfer shaft locknut. {The
locknut has left-hand threads,)
TOROUE: 118 N.m (12.0 kgf.m, 87 lbt.ft)
Stake the locknut on the transfer shaft using a 3.5
mm ounch.
al
14 mm ALI-EN WRENGH
0.7 - 1.2.nm{0.0:1- 0.C5 in}PU CH3.0 - 3.5 rnm
Total Starting Tolqu€ Insp€ction and Adiustment
32. TemDorarilv install transter cover A without the O-
flng.
HOUSING
TMNSFER COVER A
e
€
v
E- 8x1.25mm24 N'm {2.i1kgt'm, r? bt'ftl
Secure the transfer housing in a bench vise with
soft jaws, then rotate the companion flange several
times to fit the tapered roller bearing. To prevent
damage, always use soft jaws or equivalent materi-
als betlveen the transfer housing and the vise.
Measure the total starting torque.
TOTAL STARTING TOROUE:
1.70 - 2.08 N.m {17.3 - 21.2kgl.cm,15.0 - 18.i1 lbf.in}
+ Transler Driven Gear Sh8ft Starting Torque Value
lwroto down in step 27).
(cont'd)
5J.
34.
14-247
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Page 764 of 1395
Transfer Assembly
35.
Reassembly (cont'dl
36.
Remove taansfer cover A.
lf the measurement is out of specification, remove
the 68 mm thrust shim from transfer cover A by
heating the cover to almost 212"F (100"C) using a
heat gun. Do not heat the cover higher than 212"F(100'C). Let the cover cool to room temperature
before adjusting the starting torque,
lf the measurement is within the specification, go to
step 40.
HEAT GUN
14-248
37. Select the 68 mm thrust shim.
THRUST SHIM, 58 mm
Shim No.Part NumberThickness
zv23974-P1C-O201.41 mm (0.056 in)
zw23975-P1C-O201.44 mm (0.057 in)
zx23976-P1C-020'1.47 mm (0.058 in)
ZY23977 - P1C - O201.50 mm (0.059 in)
zz23978-P1C-0201.53 mm 10.060 in)
23941 PW5 - 000'1.56 mm {0.061 in)
B23942-PWs-0001.59 mm 10.063 in)
c23943 - PWs 0001.62 mm (0.064 in)
D23944-PW5-0001.65 mm {0.065 in}
E23945 PWs - 0001.68 mm (0.066 in)
F23946 PWs - 0001.71 mm (0.067 in)
G23947 PWs - 0001.74 mm (0.069 ini
23948-PW5-0001.77 mm (0.070 ini
23949 PW5 0001.80 mm (0.071 in,
J23950-PWs-0001.83 mm {0.072 ini
K23951 - PWs - 0001.86 mm (0.073 in
L23952 PW5 - 0001.89 mm (0.074 in
23953 PWs - 0001.92 mm (0.076 in
N23954 PW5 - 0001.95 mm (0.077 in
o23955 PW5 0001.98 mm (0.078 in
P23956 - PWs 0002.01 mm (0.079 in
o23957-PW5-0002.04 mm (0.080 in
R23958, PWs 0002.07 mm (0.081 in
s23959-PW5-0002.10 mm (0.083 in
T23960 PW5 - 0002.13 mm (0.084 in
U2396'1 PW5 - 0002.16 mm (0.085 in
23962 PWs 0002.19 mm (0.086 in
23963 - PW5 0002.22 mm (0.087 in
X23964 - PW5 0002.25 mm (0.089 in
23965 PW5 - 0002.28 mm (0.090 in
z23966 PWs 0002.31 mm (0.091 in
23967-PWs-0002.34 mm (0.092 in
AB23968-PWs-0002.37 mm (0.093 in)
AC23969-PWs-0002.40 mm (0.094 in)
AD23970-PW5-0002.43 mm (0.096 in)
M23941 PW8 0002.46 mm (0.097 in)
BZ23942-PW8-0002.49 mm (0.098 in)
cz23943 - PW8 0002.52 mm (0.099 in)
DZ23944 PW8 - 0002.55 mm (0.100 in)
EZ23945-PW8-0002.58 mm (0.102 in)
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Page 770 of 1395
Transmission
28.
Reassembly (cont'd)
PARX GEAR
ONE.WAY CLUTCH
BEARING
Install the mainshaft speed ssnsor (with new O-ring) on the transmission housing.
Install the park lever on the control shaft, theninstall the lock bolt with a new lock washer. Do notbend the lock tab of the lock washer in this step;bend it after checking the park pawl engagement instep 45.
Assemble the one-way clutch and the park gear onthe countershaft 1st gear (see page l4-2Og).
Lubricate these pans with ATF:. Countershaft threads. Old locknut threads and flat end. Old conical spring washer. Park gear contact area with conical springwasner
Install the countershaft 1st gear collar, needle bear-ing, and the countershaft 1st gear/park gear assem-bly on the countershaft.
Install the park pawl shaft. pawl spring, pawl. andpawl stop on the transmission housing, thenengage the pawl with th€ park gear.
31.
PAWL
I
I
a
STOP
LOCK BOLT
PAWL SHAFT
COUNIERSHAFTCOUNTERSHAFTlST GEAR COLLAR
14-254
33. Install the old locknut and the old conical springwasher on ths countershaft. Tighten the old locknutto seat the park gear to the specified torque, thenremove th€ washer and locknut. The locknut hasleft-hand threads. Do not use an impact wrench.Always use a torque wrench to tighten the locknut.
TOROUE: 103 N.m {10.5 kgf.m, 75.9 lbnft)
34. Slip the specialtool ontothe mainshaft.
MAINSHAFT07GAB - PF50101 or07GAB - PF501q)
PARK GEAR
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