Transmission and Differential.pdf - Ken Gilbert

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If the gap between the end faces of the ring and the gear splined part is excessively small when the ring is pressed against the cone. Clearance (A): 0.5 — 1.0 mm (0.020 — 0.040 in) S3M0188A When the contact surface of the synchronizer ring insert is scored or abnormally worn down. 5) Shifting insert Replace the insert if deformed, excessively worn, or defective in any way. S3M0189A 6) Oil seal Replace the oil seal if the lip is deformed, hardened, damaged, worn, or defective in any way. 7) O-ring Replace the O-ring if the sealing face is deformed, hardened, damaged, worn, or defective in any way. 8) Gearshift mechanism Repair or replace the gearshift mechanism if excessively worn, bent, or defective in any way. SERVICE PROCEDURE 15 9) Differential gear Repair or replace the differential gear in the following cases: The hypoid drive gear and drive pinion shaft tooth surface are damaged, excessively worn, or seized. The roller bearing on the drive pinion shaft has a worn or damaged roller path. There is damage, wear, or seizure of the differential bevel pinion, differential bevel gear, washer, pinion shaft, and straight pin. The differential case has worn or damaged sliding surfaces. (A) Drive pinion shaft (B) Hypoid driven gear (C) Pinion shaft (D) Straight pin (E) Washer (F) Differential bevel gear (G) Differential bevel pinion (H) Snap ring (I) Roller bearing (J) Differential case [W1B0] 3-1 1. General B3M0558B
3-1 [W2A1] SERVICE PROCEDURE 2. Transmission Case 2. Transmission Case A: DISASSEMBLY 1. SEPARATION OF TRANSMISSION (1) Operating cylinder (2500 cc model) (2) Release lever (2200 cc model) (3) Release lever (2500 cc model) (4) Release bearing (5) Release lever sealing (6) Bolt (7) Main shaft rear plate 1) Remove clutch release lever. (A) Clutch release lever (B) Release bearing B3M0336I 2) Remove transfer case assembly. 16 (8) Transmission case (9) Drive pinion ASSY (10) Main shaft ASSY (11) Front differential 3) Remove bearing mounting bolts. B3M0614G S3M0099
Page 1 and 2: 3-1 [S100] SPECIFICATIONS AND SERVI
Page 3 and 4: 3-1 [S600] SPECIFICATIONS AND SERVI
Page 5 and 6: 3-1 [C100] COMPONENT PARTS 1. Trans
Page 7 and 8: 3-1 [C2B0] COMPONENT PARTS 2. Drive
Page 9 and 10: 3-1 [C3B0] COMPONENT PARTS 3. Main
Page 11 and 12: 3-1 [C500] COMPONENT PARTS 5. Trans
Page 13: 3-1 [W1A0] SERVICE PROCEDURE 1. Gen
Page 17 and 18: 3-1 [W2A2] SERVICE PROCEDURE 2. Tra
Page 19 and 20: 3-1 [W2B1] SERVICE PROCEDURE 2. Tra
Page 29 and 30: 3-1 [W3A1] SERVICE PROCEDURE 3. Dri
Page 31 and 32: 3-1 [W3B0] SERVICE PROCEDURE 3. Dri
Page 33 and 34: 3-1 [W3B3] SERVICE PROCEDURE 3. Dri
Page 35 and 36: 3-1 [W3C1] SERVICE PROCEDURE 3. Dri
Page 37 and 38: 3-1 [W4A1] SERVICE PROCEDURE 4. Mai
Page 39 and 40: 3-1 [W4B0] SERVICE PROCEDURE 4. Mai
Page 41 and 42: 3-1 [W4B2] SERVICE PROCEDURE 4. Mai
Page 43 and 44: 3-1 [W5A0] SERVICE PROCEDURE 5. Tra
Page 47 and 48: 3-1 [W5C3] SERVICE PROCEDURE 5. Tra
Page 49 and 50: 3-1 [W5D0] SERVICE PROCEDURE 5. Tra
Page 51 and 52: 3-1 [W6B0] SERVICE PROCEDURE 6. Fro
Page 53 and 54: 3-1 [W7A0] SERVICE PROCEDURE 7. Cen
Page 55 and 56: 3-1 [K200] DIAGNOSTICS 2. Different
Page 57 and 58: 3. Transmission Control Element Typ
Page 59 and 60: 7. Hydraulic Control and Lubricatio
Page 61 and 62: 3-2 [S1100] SPECIFICATIONS AND SERV
Page 63 and 64: 3-2 [S1100] SPECIFICATIONS AND SERV
Page 65 and 66:
No. Part Name Part Number (1) (2) (
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C: TRANSMISSION CASE (REAR SIDE) (1
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G: EXTENSION CASE SPECIFICATIONS AN
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2. Oil Pump (1) Oil pump rotor (2)
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(1) Oil level gauge (2) Oil charger
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5. High Clutch and Reverse Clutch (
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7. Low Clutch and Low & Reverse Bra
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9. Differential Case (1) Crown gear
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1. General A: PRECAUTION When disas
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2) Torque converter clutch case En
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C: REMOVAL 1) Move select lever to
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3. Sensor (in transmission) A: INSP
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5) Remove control valve body. CAUTI
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5. Transfer Duty Solenoid and Trans
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2) Install extension case to transm
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CAUTION: Align ST with torque wrenc
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3. ENGINE BRAKE OPERATION Engine br
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3. EVALUATION Stall speed (at sea l
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2. TEST METHODS 1) Temporarily atta
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12. Overall Transmission A: SECTION
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10) Remove the oil cooler inlet and
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6) Remove the oil pan. NOTE: Use a
Page 109 and 110:
19) Take out the thrust needle bear
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34) Remove parking support. B3M1088
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(2) Tighten four bolts to secure th
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Checking item Contact pattern Corre
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13) Apply vaseline to the groove on
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(1) Using a press and ST1, install
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19) Install planetary gear and low
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(2) Using ST, measure the distance
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4) Install the oil pan. (1) Attach
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(2) Measure the distance “ ” fr
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7) Install the oil charge pipe. CAU
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14. Reduction Driven Gear A: DISASS
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No. Part name SERVICE PROCEDURE Wir
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D: ASSEMBLY 1) Install accumulator
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5) Remove the inner and outer rotor
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C: ASSEMBLY 1) Measure dimension
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18. High Clutch and Reverse Clutch
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C: ASSEMBLY (1) Reverse clutch drum
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10) Apply compressed air intermitte
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19. Low Clutch Drum and Planetary G
Page 149 and 150:
9) Install the one-way clutch inner
Page 151 and 152:
4) Install ST to low clutch drum. S
Page 153 and 154:
15) Install rear sun gear. NOTE: Pa
Page 155 and 156:
4) Measurement of backlash (Selecti
Page 157 and 158:
6) Using ST1 and ST2, install snap
Page 159 and 160:
23. Transmission Control Module (TC
Page 161 and 162:
3-3 [C100] COMPONENT PARTS 1. Manua
Page 163 and 164:
3-3 [W1A0] SERVICE PROCEDURE 1. Man
Page 165 and 166:
3-3 [W1E0] SERVICE PROCEDURE 1. Man
Page 167 and 168:
3-3 [W2C0] SERVICE PROCEDURE 2. Aut
Page 169 and 170:
3-4 [S1A0] SPECIFICATIONS AND SERVI
Page 171 and 172:
3-4 [S2C1] SPECIFICATIONS AND SERVI
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3-4 [S2C3] SPECIFICATIONS AND SERVI
Page 175 and 176:
3-4 [C2A0] COMPONENT PARTS 2. Rear
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3-4 [C2B2] COMPONENT PARTS 2. Rear
Page 179 and 180:
3-4 [W1A0] SERVICE PROCEDURE 1. Pro
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3-4 [W1F0] SERVICE PROCEDURE 1. Pro
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3-4 [W2A2] SERVICE PROCEDURE 2. Rea
Page 185 and 186:
3-4 [W2B0] SERVICE PROCEDURE 2. Rea
Page 187 and 188:
3-4 [W2C0] SERVICE PROCEDURE 2. Rea
Page 189 and 190:
Page 191 and 192:
3-4 [W2E0] SERVICE PROCEDURE 2. Rea
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Page 195 and 196:
Page 197 and 198:
Page 199 and 200:
Page 201 and 202:
Page 203 and 204:
Page 205 and 206:
3-4 [W3B0] SERVICE PROCEDURE 3. Rea
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Page 209 and 210:
3-4 [W3D0] SERVICE PROCEDURE 3. Rea
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Page 213 and 214:
Page 215 and 216:
Page 217 and 218:
Page 219 and 220:
Page 221 and 222:
3-4 [K100] DIAGNOSTICS 1. Propeller
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