Page 2105 of 2453

5AT-89
Front Differential Assembly
AUTOMATIC TRANSMISSION
2. SIDE RETAINER
NOTE:
Install the oil seal and O-ring of side retainer after
the adjustment of backlash and tooth contact.
1) Install the bearing outer race to side retainer.
2) Install a new oil seal using ST.
ST 18675AA000 DIFFERENTIAL SIDE OIL
SEAL INSTALLER
NOTE:
Apply oil to the oil seal lips.
3) Install a new O-ring.
E: INSPECTION
•Check each component for scratches, damage
or other faults.
•Measure the backlash, and then adjust it to be
within specification.
Assembly.>
F: ADJUSTMENT
1) Using the ST, screw-in the retainer until resis-
tance is felt.
NOTE:
Screw in the RH side slightly deeper than the LH
side.
ST 18630AA010 WRENCH
2) Remove the oil pump cover.
3) Remove the liquid gasket from the mating sur-
face completely.
4) Install the oil pump cover to converter case, and
secure them with tightening four bolts evenly.
NOTE:
Use an old gasket or aluminum washer to prevent
damaging the mating surface of the housing.
Tightening torque:
41 N·m (4.2 kgf-m, 30.4 ft-lb)
5) Rotate the drive pinion ten times or more using
ST1 and ST2.
ST1 18667AA010 HOLDER
ST2 499787700 WRENCH
AT-00226
ST
AT-00219
AT-00227
ST
AT-01985
ST2ST1
Page 2106 of 2453

5AT-90
Front Differential Assembly
AUTOMATIC TRANSMISSION
6) Tighten the LH retainer by rotating the shaft until
resistance is felt. Then loosen the retainer RH.
Keep tightening the retainer LH, and loosening the
retainer RH until the pinion shaft no longer be
turned. This is the “zero” state.
7) After the “zero” state is established, back off the
retainer LH 3 notches and secure it with the lock
plate. Then back off the retainer RH and retighten
until it stops. Rotate the drive pinion 2 or 3 times.
Tighten the retainer RH further 1-3/4 notches. This
sets the preload. Finally, secure the retainer with its
lock plate.
NOTE:
Turning the retainer by one tooth changes the
backlash approx. 0.05 mm (0.0020 in).
8) Turn the drive pinion several times using ST1,
and check to see if the backlash is within the spec-
ification using ST2, ST3, ST4 and ST5.
ST1 499787700 WRENCH
ST2 498247001 MAGNET BASE
ST3 498247100 DIAL GAUGE
ST4 499787500 ADAPTER
ST5 498255400 PLATE
Backlash:
0.10 — 0.15 mm (0.0039 — 0.0059 in)
9) Adjust the teeth contact of the front differential
and drive shaft.
Drive Pinion Shaft Assembly.>
(A) Retainer
(A) Lock plate
(A) 0.05 mm (0.0020 in)
AT-01986
(A)
AT-01988
(A)
AT-01989
(A)
Page 2107 of 2453

5AT-91
AT Main Case
AUTOMATIC TRANSMISSION
34.AT Main Case
A: REMOVAL
1) Remove the transmission assembly from vehicle
body.
Transmission Assembly.>
2) Pull out the torque converter assembly.
5AT-62, REMOVAL, Torque Converter Assembly.>
3) Remove the transmission harness connector
from stay.
4) Disconnect the air breather hose.
5) Remove the oil charge pipe.
REMOVAL, Oil Charge Pipe.>
6) Remove the ATF filter inlet and outlet pipes.
Hose.>
7) Remove the extension case.
REMOVAL, Extension Case.>
8) Remove the center differential carrier.
5AT-71, REMOVAL, Center Differential Carrier.>
9) Remove the reduction driven gear.
68, REMOVAL, Reduction Driven Gear.>
10) Separate the converter case from the transmis-
sion case.
Case.>
11) Remove the control valve body.
53, REMOVAL, Control Valve Body.>
12) Remove the oil pump cover.
NOTE:
The input clutch pack assembly and front sun gear
assembly are also removed together.
13) Remove the needle bearing of the middle carri-
er assembly.
14) Remove the middle carrier assembly.
15) Remove the rear carrier assembly.
AT-01990
AT-01991
AT-01992
AT-01993
Page 2108 of 2453
5AT-92
AT Main Case
AUTOMATIC TRANSMISSION
16) Remove the middle & rear sun gear assembly.
17) Remove the thrust needle bearing of high & low
reverse clutch.
18) Remove the high & low reverse clutch assem-
bly.
19) Remove the direct clutch assembly.
20) Remove the snap ring of reverse brake.
21) Remove the retaining plate.
22) Remove the leaf spring.
23) Take out the drive plate, driven plate and dish
plate.
AT-01994
AT-01995
AT-01996(A) Leaf spring
AT-01997
AT-01998
B'B
B' B
(A)
(A)AT-03364
Page 2109 of 2453
5AT-93
AT Main Case
AUTOMATIC TRANSMISSION
24) Remove the snap ring of the reverse brake
spring retainer.
ST1 18762AA000 COMPRESSOR SPECIAL
TOOL
ST2 18765AA000 COMPRESSOR SUPPORT
ST3 18763AA000 COMPRESSOR SHAFT
25) Remove the spring retainer.
26) Remove the return spring.
27) Apply compressed air.
28) Remove the reverse brake piston.
B: INSTALLATION
1) Install the reverse brake piston.
NOTE:
Apply ATF onto the piston sliding surface.
ST1 18762AA000 COMPRESSOR SPECIAL
TOOL
ST2 18765AA000 COMPRESSOR SUPPORT
ST3 18763AA000 COMPRESSOR SHAFT
2) Install the return spring.
AT-02000
ST3
ST2
ST1
AT-02001
AT-02002
AT-02004
AT-02005
AT-02002
Page 2110 of 2453

5AT-94
AT Main Case
AUTOMATIC TRANSMISSION
3) Install the spring retainer and snap ring.
ST1 18762AA000COMPRESSOR SPECIAL TOOL
ST2 18765AA000 COMPRESSOR SUPPORT
ST3 18763AA000 COMPRESSOR SHAFT
4) Install the dish plate.
NOTE:
When installing, make sure that the identification
mark is facing the front side of transmission.
5) Install the drive plate and driven plate.
6) Install the leaf spring.
7) Install the retaining plate.
8) Install the snap ring of the reverse brake.
9) Perform the clearance check of reverse brake.
(1) Measure the clearance between retainer
plate and snap ring using thickness gauge.
Specification:
0.7 — 1.1 mm (0.028 — 0.043 in)
(2) If it is out of specification, select a suitable
retainer plate from the following table and as-
semble it.
10) Install the direct clutch assembly.
(A) Leaf spring
AT-02000
ST3
ST2
ST1
B'B
B' B
(A)
(A)AT-03364
Retainer plate
Par t N o. Thickness mm (in)
31567AB100 4.2 (0.165)
31567AB170 4.4 (0.173)
31567AB180 4.6 (0.181)
31567AB190 4.8 (0.189)
31567AB200 5.0 (0.197)
AT-01998
AT-02372
AT-01997
Page 2111 of 2453
5AT-95
AT Main Case
AUTOMATIC TRANSMISSION
11) Install the high & low reverse clutch assembly.
12) Install the thrust needle bearing of the high &
low reverse clutch.
13) Install the middle & rear sun gear assembly.
14) Install the rear carrier assembly.
15) Install the middle carrier assembly.
AT-01996
AT-01995
AT-01994
AT-01993
AT-01992
Page 2112 of 2453

5AT-96
AT Main Case
AUTOMATIC TRANSMISSION
16) Install the thrust needle bearing of middle carri-
er assembly.
17) Measure the total end play, and select the
bearing.
Case.>
18) Install the impact clutch pack assembly to oil
pump cover.
19) Install the thrust needle bearing.
20) Turn the transmission sideways.
21) Install the oil pump cover.
(1) Apply ATF to the O-ring of input clutch shaft.
(2) Install the oil pump cover to AT main case
while supporting the input clutch shaft and oil
pump housing with your hand.
(3) Make sure the rear end of drive pinion shaft
is engaged to the spline of reduction driven
gear.
(4) Protect the input clutch shaft with a cloth,
and rotate to engage the spline of the input
clutch and rear carrier using pliers.
NOTE:
Work with pressing the oil pump cover.
(5) Combine the oil pump cover with transmis-
sion main case.
Tightening torque:
41 N·m (4.2 kgf-m, 30.4 ft-lb)
22) Install the center differential carrier.
5AT-71, INSTALLATION, Center Differential Carri-
er.>
23) Install the reduction driven gear.
68, INSTALLATION, Reduction Driven Gear.>
(A) Impact clutch pack ASSY
(B) Front sun gear ASSY
AT-01991
AT-02006
(A)
(B)
AT-01990
(A) Drive pinion shaft
(A) Cloth
AT-02092(A)
AT-02046(A)
AT-01976