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DISASSEMBLY
AT-277
D
E
F
G
H
I
J
K
L
MA
B
AT
Revision: October 20052005 QX56
63. Remove manual shaft oil seals using a flat-bladed screwdriver.
CAUTION:
Be careful not to scratch transmission case.
64. Remove detent spring and spacer from transmission case.
65. Remove snap ring from transmission case, using suitable tool.
66. Remove servo assembly (with return spring) from transmission
case.
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AT-298
ASSEMBLY
Revision: October 20052005 QX56
ASSEMBLYPFP:00000
Assembly (1)ECS00CLC
1. Use a drift [commercial service tool φ22 mm (0.87 in)] to drive
manual shaft oil seals into the transmission case until it is flush
as shown.
CAUTION:
Apply ATF to manual shaft oil seals.
Do not reuse manual shaft oil seals.
2. Install detent spring and spacer in transmission case. Tighten
bolt to the specified torque. Refer to AT-250, "
Components" .
3. Install manual shaft to transmission case.
4. Install parking rod to manual plate.
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ASSEMBLY
AT-303
D
E
F
G
H
I
J
K
L
MA
B
AT
Revision: October 20052005 QX56
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:
Take care with the direction of needle bearing. Refer to
AT-260, "
Locations of Adjusting Shims, Needle Bearings,
Thrust Washers and Snap Rings" .
Apply petroleum jelly to needle bearing.
24. Install revolution sensor to transmission case. Tighten revolution
sensor bolt to the specified torque. Refer to AT-250, "
Compo-
nents" .
CAUTION:
Do not subject it to impact by dropping or hitting it.
Be careful not to damage harness with the edge of case.
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. Install new rear oil seal into the rear extension (2WD models) or
adapter case (4WD models) until it is flush with component face,
using Tool or suitable drift.
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-323, "
Reverse brake" .
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ASSEMBLY
AT-305
D
E
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H
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AT
Revision: October 20052005 QX56
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 in output shaft.
34. Install rear extension assembly (2WD models) or adapter case assembly (4WD models) according to the
following procedures.
a.2WD models
i. Apply recommended sealant (Genuine Anaerobic Liquid Gasket
or equivalent. Refer to GI-45, "
Recommended Chemical Prod-
ucts and Sealants" .) to rear extension assembly as shown.
CAUTION:
Complete remove all moisture, oil and old sealant, etc.
From the transmission case and rear extension assembly
mounting surfaces.
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AT-306
ASSEMBLY
Revision: October 20052005 QX56
ii. Install rear extension assembly to transmission case.
iii. Install bracket.
iv. Tighten rear extension assembly bolts to specified torque.
CAUTION:
Do not reuse self-sealing bolt.
b.4WD models
i. Install new gasket to transmission case.
CAUTION:
Do not reuse gasket.
Complete remove all moisture, oil and old gasket, etc.
From the transmission case and adapter case assembly
mounting surfaces.
ii. Install adapter case assembly to transmission case.
SCIA5029E
Rear extension assembly
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-312
ASSEMBLY
Revision: October 20052005 QX56
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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ASSEMBLY
AT-313
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Revision: October 20052005 QX56
b. Measure dimension “M1 ”.
c. Measure dimension “M
2 ”.
d. Calculate dimension “M”.
3. Adjust total end play “T
1 ”.
Select proper thickness of bearing race so that total end play
is within specifications.
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SCIA3127E
“M”: Distance between transmission case fitting sur-
face of oil pump and needle bearing on oil pump.
M = M
1 – M2
SCIA3125E
T1 = J – M
Total end play “T
1 ”:
0.25 - 0.55 mm (0.0098 - 0.0217 in)
Bearing races:
Refer to AT-323, "
BEARING RACE FOR ADJUST-
ING TOTAL END PLAY" .SCIA2810E
Page 385 of 3419
AT-314
ASSEMBLY
Revision: October 20052005 QX56
Assembly (2)ECS00CLE
1. Install new O-ring to oil pump assembly.
CAUTION:
Do not reuse O-ring.
Apply ATF to O-ring.
2. Install bearing race to oil pump assembly.
CAUTION:
Apply petroleum jelly to bearing race.
3. Install oil pump assembly in transmission case.
CAUTION:
Apply ATF to oil pump radial bearing.
4. Apply recommended sealant (Genuine RTV Silicone Sealant or
equivalent. Refer to GI-45, "
Recommended Chemical Products
and Sealants" .) to oil pump assembly as shown.
CAUTION:
Complete remove all moisture, oil and old sealant, etc.
From the oil pump bolts and oil pump bolt surfaces.
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