Page 374 of 4449

DISASSEMBLY
AT-297
D
E
F
G
H
I
J
K
L
MA
B
AT
Revision: 2004 November 2004 FX35/FX45
45. Remove needle bearing from transmission case.
46. Remove revolution sensor from transmission case.
CAUTION:
Do not subject it to impact by dropping or hitting it.
Do not disassemble.
Do not allow metal filings, etc., to get on the sensor's
front edge magnetic area.
Do not place in an area affected by magnetism.
47. Remove reverse brake snap ring (fixing plate) using 2 flat-
bladed screwdrivers.
NOTE:
Press out snap ring from the transmission case oil pan side gap
using a flat-bladed screwdriver, and remove it using another
screwdriver.
48. Remove reverse brake retaining plate from transmission case.
Check facing for burns, cracks or damage. If necessary,
replace the plate.
49. Remove N-spring from transmission case.
50. Remove reverse brake drive plates, driven plates and dish plate
from transmission case.
Check facing for burns, cracks or damage. If necessary,
replace the plate.
SCIA5031E
SCIA2320E
SCIA5032E
SCIA5214E
SCIA2322E
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DISASSEMBLY
AT-299
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Revision: 2004 November 2004 FX35/FX45
55. Remove reverse brake piston from transmission case with com-
pressed air. Refer to AT- 2 8 2 , "
Oil Channel" .
CAUTION:
Care should be taken not to abruptly blow air. It makes pis-
tons incline, as the result, it becomes hard to disassemble
the pistons.
56. Remove lip seal and D-ring from reverse brake piston.
57. Use a pin punch (4mm dia. commercial service tool) to knock
out retaining pin.
58. Remove manual shaft retaining pin with nippers.
SCIA5047E
SCIA2795E
SCIA2328E
SCIA2329E
Page 377 of 4449
AT-300
DISASSEMBLY
Revision: 2004 November 2004 FX35/FX45
59. Remove manual plate (with parking rod) from manual shaft.
60. Remove parking rod from manual plate.
61. Remove manual shaft from transmission case.
62. Remove manual shaft oil seals using a flat-bladed screwdriver.
CAUTION:
Be careful not to scratch transmission case.
63. Remove detent spring and spacer from transmission case.
SCIA5715E
SCIA5220E
SCIA5716E
SCIA2331E
SCIA5248E
Page 402 of 4449
ASSEMBLY
AT-325
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Revision: 2004 November 2004 FX35/FX45
ASSEMBLYPFP:00000
Assembly (1)ACS007HD
1. As shown in the right figure illustration, use a drift [commercial
service tool φ22mm (0.87in)] to drive manual shaft oil seals into
the transmission case until it is flush.
CAUTION:
Apply ATF to manual shaft oil seals.
Do not reuse manual shaft oil seals.
2. Install detent spring and spacer in transmission case.
3. Install manual shaft to transmission case.
4. Install parking rod to manual plate.
SCIA5259E
: 7.9 N·m (0.81 kg-m, 70 in-lb)
SCIA5248E
SCIA5716E
SCIA5220E
Page 407 of 4449
AT-330
ASSEMBLY
Revision: 2004 November 2004 FX35/FX45
22. Measure clearance between retaining plate and snap ring. If not
within specified clearance, select proper retaining plate.
23. Install needle bearing to transmission case.
CAUTION:
Apply petroleum jelly to needle bearing.
24. Install revolution sensor to transmission case.
CAUTION:
Do not subject it to impact by dropping or hitting it.
Do not disassemble.
Do not allow metal filings, etc., to get on the sensor's
front edge magnetic area.
Do not place in an area affected by magnetism.
25. As shown in the right figure illustration, use the drift to drive rear
oil seal into the rear extension (2WD models) or adapter case
(AWD models) until it is flush.
CAUTION:
Apply ATF to rear oil seal.
Do not reuse rear oil seal.Specified clearance “A”:
Standard: 0.7 - 1.1mm (0.028 - 0.043 in)
Retaining plate:
Refer to AT- 3 5 0 , "
Reverse Brake" .
SCIA3129E
SCIA5031E
: 5.8 N·m (0.59 kg-m, 51 in-lb)
SCIA2320E
SCIA5477E
Page 409 of 4449
AT-332
ASSEMBLY
Revision: 2004 November 2004 FX35/FX45
31. Install parking gear to output shaft.
32. Install output shaft in transmission case.
CAUTION:
Be careful not to mistake front for rear because both sides
looks similar. (Thinner end is front side.)
33. Install bearing race to output shaft.
34. Install rear extension assembly (2WD models) or adapter case assembly (AWD models) according to the
following procedures.
a.2WD models
i. Apply recommended sealant (Genuine Anaerobic Liquid Gasket
or equivalent. Refer to GI-48, "
Recommended Chemical Prod-
ucts and Sealants" .) to rear extension assembly as shown in
illustration.
CAUTION:
Completely remove all moisture, oil and old sealant, etc.
from the transmission case and rear extension assembly
mounting surfaces.
SCIA5247E
SCIA5030E
SCIA5245E
SCIA5212E
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ASSEMBLY
AT-333
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Revision: 2004 November 2004 FX35/FX45
ii. Install rear extension assembly to transmission case.
CAUTION:
Insert the tip of parking rod between the parking pawl and
the parking actuator support when assembling the rear
extension assembly.
iii. Tighten rear extension assembly mounting bolts to specified
torque.
CAUTION:
Do not reuse self-sealing bolt.
b.AWD models
i. Install gasket onto transmission case.
CAUTION:
Completely remove all moisture, oil and old gasket, etc.
from the transmission case and adapter case assembly
mounting surfaces.
Do not reuse gasket.
ii. Install adapter case assembly to transmission case.
CAUTION:
Insert the tip of parking rod between the parking pawl and
the parking actuator support when assembling the adapter
case assembly.
SCIA5029E
Rear extension assembly mounting bolt:
: 52 N·m (5.3 kg-m, 38 ft-lb)
Self-sealing bolt:
: 61 N·m (6.2 kg-m, 45 ft-lb)
SCIA3426E
SCIA5231E
SCIA5186E
Page 416 of 4449
ASSEMBLY
AT-339
D
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AT
Revision: 2004 November 2004 FX35/FX45
1. Measure dimensions “K” and “L” and then calculate dimension
“J”.
a. Measure dimension “K”.
b. Measure dimension “L”.
c. Calculate dimension “J”.
2. Measure dimensions “M
1 ” and “M2 ” and then calculate dimen-
sion “M”.
a. Place bearing race and needle bearing on oil pump assembly.
SCIA5350E
SCIA5351E
“J”: Distance between oil pump fitting surface of
transmission case and needle bearing mating surface
of front sun gear.
J = K – L
SCIA5352E
SCIA3125E
SCIA3124E