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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.
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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)
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AT-334
ASSEMBLY
Revision: 2004 November 2004 FX35/FX45
iii. Tighten adapter case assembly mounting bolts to specified
torque. (With bracket.)
CAUTION:
Do not reuse self-sealing bolt.
35. Install needle bearing in drum support.
CAUTION:
Apply petroleum jelly to needle bearing.
36. Install direct clutch assembly in reverse brake.
CAUTION:
Make sure that drum support edge surface and direct clutch
inner boss edge surface come to almost same place.
37. Install high and low reverse clutch assembly in direct clutch.Adapter case 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)
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38. Using a flat-bladed screwdriver, adjust the drive plate.
39. Install high and low reverse clutch hub, mid sun gear assembly
and rear sun gear assembly in high and low reverse clutch.
CAUTION:
Check that portion A of high and low reverse clutch drum
protrudes approximately 2 mm (0.08 in) beyond portion B of
rear sun gear.
40. Install needle bearing in rear carrier assembly.
CAUTION:
Apply petroleum jelly to needle bearing.
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AT-336
ASSEMBLY
Revision: 2004 November 2004 FX35/FX45
41. Install bearing race in rear carrier assembly.
CAUTION:
Apply petroleum jelly to bearing race.
42. Install rear carrier assembly in direct clutch drum.
43. Install needle bearing (rear side) to mid carrier assembly.
CAUTION:
Apply petroleum jelly to needle bearing.
44. Install needle bearing (front side) to mid carrier assembly.
CAUTION:
Apply petroleum jelly to needle bearing.
45. Install mid carrier assembly in rear carrier assembly.
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46. Install front carrier assembly (With input clutch assembly and
rear internal gear.) to rear carrier assembly.
47. Install seal rings in input clutch assembly.
CAUTION:
Do not reuse seal rings.
Apply petroleum jelly to seal rings.
48. Install band servo anchor end pin and lock nut in transmission
case.
CAUTION:
Do not reuse band servo anchor end pin.
49. Install brake band in transmission case.
CAUTION:
Assemble it so that identification to avoid incorrect installa-
tion faces servo side.
50. Install front sun gear to front carrier assembly.
CAUTION:
Apply ATF to front sun gear bearing and 3rd one-way clutch
end bearing.
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AT-338
ASSEMBLY
Revision: 2004 November 2004 FX35/FX45
51. Install needle bearing to front sun gear.
CAUTION:
Apply petroleum jelly to needle bearing.
52. Adjust brake band tilting using clips so that brake band contacts
front sun gear drum evenly.
53. Adjust brake band.
a. Loosen lock nut.
b. Tighten band servo anchor end pin to specified torque.
c. Back of band servo anchor end pin three turns.
d. Holding band servo anchor end pin, tighten lock nut to specified
torque.
AdjustmentACS007HE
TOTAL END PLAY
Measure clearance between front sun gear and bearing race for
oil pump cover.
Select proper thickness of bearing race so that end play is within
specifications.
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: 5.0 N·m (0.51 kg-m, 44 in-lb)
: 46 N·m (4.7 kg-m, 34 ft-lb)
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ASSEMBLY
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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.
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“J”: Distance between oil pump fitting surface of
transmission case and needle bearing mating surface
of front sun gear.
J = K – L
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