Transmission and Differential.pdf - Ken Gilbert

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3) Drive out straight pin, and pull out 3-4 fork rod and shifter fork. NOTE: When removing rod, keep other rods in neutral. Also, when pulling out straight pin, remove it toward inside of case so that it may not hit against case. (A) Straight pin (B) 3-4 fork rod (C) Shifter fork B3M0523C 4) Drive out straight pin, and pull out 1-2 fork rod and shifter fork. 5) Pull out straight pin, and remove idler gear shaft, reverse idler gear and washer. (A) Straight pin (B) Idler gear shaft (C) Idler gear (D) Washer SERVICE PROCEDURE B3M0524C 19 6) Remove outer snap ring, and pull out reverse shifter rod arm from reverse fork rod. Then take out ball, spring and interlock plunger from rod. And then remove rod. NOTE: When pulling out reverse shifter rod arm, be careful not to let ball pop out of arm. 7) Remove reverse shifter lever. 8) Remove differential side retainers using ST. ST 499787000 WRENCH ASSY B3M1360A 9) Remove outer snap ring and pull out speedometer driven gear. Next, remove vehicle speed sensor 2, oil seal, speedometer shaft and washer. (A) Outer snap ring (B) Speedometer driven gear [W2A2] 3-1 2. Transmission Case B3M0525C
3-1 [W2B1] SERVICE PROCEDURE 2. Transmission Case B: ASSEMBLY 1. TRANSMISSION CASE (1) Reverse shifter lever (2) Reverse idler gear (3) Reverse idler gear shaft (4) Straight pin (5) Reverse fork rod arm (6) Reverse fork rod (7) Snap ring (8) Ball (9) Checking ball spring (10) Gasket (11) Checking ball plug (12) Washer (13) 1st-2nd fork rod (14) 1st-2nd shifter fork (15) Straight pin (16) 3rd-4th fork rod 1) Position interlock plungers (5.56 × 19.6), one plunger in hole between 1-2 and 3-4 fork rod holes, and one plunger in hole between 3-4 and reverse fork rod holes. B3M0062D 20 (17) 3rd-4th shifter fork (18) 5th shifter fork S3M0104B Tightening torque: N·m (kg-m, ft-lb) T: 19.6±0.1 (2.00±0.015, 14.5±0.1)
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 and 14: 3-1 [W1A0] SERVICE PROCEDURE 1. Gen
Page 15 and 16: 3-1 [W2A1] SERVICE PROCEDURE 2. Tra
Page 17: 3-1 [W2A2] SERVICE PROCEDURE 2. Tra
Page 21 and 22: 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) (
Page 67 and 68: C: TRANSMISSION CASE (REAR SIDE) (1
Page 69 and 70:
G: EXTENSION CASE SPECIFICATIONS AN
Page 71 and 72:
2. Oil Pump (1) Oil pump rotor (2)
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(1) Oil level gauge (2) Oil charger
Page 75 and 76:
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
Page 87 and 88:
3. Sensor (in transmission) A: INSP
Page 89 and 90:
5) Remove control valve body. CAUTI
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5. Transfer Duty Solenoid and Trans
Page 93 and 94:
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
Page 105 and 106:
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
Page 123 and 124:
(2) Using ST, measure the distance
Page 125 and 126:
4) Install the oil pan. (1) Attach
Page 127 and 128:
(2) Measure the distance “ ” fr
Page 129 and 130:
7) Install the oil charge pipe. CAU
Page 131 and 132:
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
Page 137 and 138:
5) Remove the inner and outer rotor
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C: ASSEMBLY 1) Measure dimension
Page 141 and 142:
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
Page 147 and 148:
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
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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
Page 173 and 174:
3-4 [S2C3] SPECIFICATIONS AND SERVI
Page 175 and 176:
3-4 [C2A0] COMPONENT PARTS 2. Rear
Page 177 and 178:
3-4 [C2B2] COMPONENT PARTS 2. Rear
Page 179 and 180:
3-4 [W1A0] SERVICE PROCEDURE 1. Pro
Page 181 and 182:
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
Page 193 and 194:
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
Page 207 and 208:
Page 209 and 210:
3-4 [W3D0] SERVICE PROCEDURE 3. Rea
Page 211 and 212:
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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Transmission and Differential.pdf - Ken Gilbert

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