Transmission and Differential.pdf - Ken Gilbert

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No. Part Name Part Number Dimension mm (in) Application 1 Rotor (Oil pump) 2 Thrust bearing 3 4 5 6 7 8 9 10 Retaining plate (High clutch) Retaining plate (Reverse clutch) Retaining plate (2-4 brake) Retaining plate (Low clutch) Retaining plate (Low <strong>and</strong> reverse brake) Pressure plate (Transfer clutch) Thrust bearing (Transfer clutch) Washer (Front differential) SPECIFICATIONS AND SERVICE DATA 15008AA060 15008AA070 15008AA080 806528050 806528060 806528070 806528080 806528090 806528100 31567AA710 31567AA720 31567AA730 31567AA740 31567AA670 31567AA680 31567AA690 31567AA700 31567AA760 31567AA770 31567AA780 31567AA790 31567AA800 31567AA610 31567AA620 31567AA630 31567AA640 31567AA650 31567AA660 31567AA830 31567AA840 31567AA850 31567AA860 31567AA870 31667AA320 31667AA330 31667AA340 31667AA350 31667AA360 31667AA370 31667AA380 31593AA151 31593AA161 31593AA171 31593AA181 806536020 806535030 806535040 806535050 806535060 806535070 806535090 803038021 803038022 803038023 11.37 — 11.38 (0.4476 — 0.4480) 11.38 — 11.39 (0.4480 — 0.4484) 11.39 — 11.40 (0.4484 — 0.4488) 4.11 (0.1618) 4.3 (0.169) 4.5 (0.177) 4.7 (0.185) 4.9 (0.193) 5.1 (0.201) 4.7 (0.185) 4.8 (0.189) 4.9 (0.193) 5.0 (0.197) 5.1 (0.201) 5.2 (0.205) 5.3 (0.209) 5.4 (0.213) 4.0 (0.157) 4.2 (0.165) 4.4 (0.173) 4.6 (0.181) 4.8 (0.189) 5.6 (0.220) 5.8 (0.228) 6.0 (0.236) 6.2 (0.244) 6.4 (0.252) 6.6 (0.260) 3.8 (0.150) 4.0 (0.157) 4.2 (0.165) 4.4 (0.173) 4.6 (0.181) 4.2 (0.165) 4.5 (0.177) 4.8 (0.189) 5.1 (0.201) 5.4 (0.213) 5.7 (0.224) 6.0 (0.236) 3.3 (0.130) 3.7 (0.146) 4.1 (0.161) 4.5 (0.177) 3.8 (0.150) 4.0 (0.157) 4.2 (0.165) 4.4 (0.173) 4.6 (0.181) 4.8 (0.189) 5.0 (0.197) 0.95 (0.0374) 1.00 (0.0394) 1.05 (0.0413) 9 [S1100] 3-2 11. Adjusting Parts Adjusting side clearance of oil pump Adjusting total end play Adjusting clearance of high clutch Adjusting clearance of reverse clutch Adjusting clearance of 2-4 brake Adjusting clearance of low clutch Adjusting clearance of low <strong>and</strong> reverse brake Adjusting clearance of transfer clutch Adjusting end play of transfer clutch Adjusting backlash of differential bevel gear
3-2 [S1100] SPECIFICATIONS AND SERVICE DATA 11. Adjusting Parts No. Part Name Part Number Dimension mm (in) Application 11 Drive pinion shim 31451AA050 31451AA060 31451AA070 31451AA080 31451AA090 31451AA100 10 0.150 (0.0059) 0.175 (0.0069) 0.200 (0.0079) 0.225 (0.0089) 0.250 (0.0098) 0.275 (0.0108) Adjusting drive pinion shim
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3-1 [S100] SPECIFICATIONS AND SERVI
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3-1 [S600] SPECIFICATIONS AND SERVI
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3-1 [C100] COMPONENT PARTS 1. Trans
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3-1 [C2B0] COMPONENT PARTS 2. Drive
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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 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 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: 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)
Page 73 and 74: (1) Oil level gauge (2) Oil charger
Page 75 and 76: 5. High Clutch and Reverse Clutch (
Page 77 and 78: 7. Low Clutch and Low & Reverse Bra
Page 79 and 80: 9. Differential Case (1) Crown gear
Page 81 and 82: 1. General A: PRECAUTION When disas
Page 83 and 84: 2) Torque converter clutch case En
Page 85 and 86: 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
Page 91 and 92: 5. Transfer Duty Solenoid and Trans
Page 93 and 94: 2) Install extension case to transm
Page 95 and 96: CAUTION: Align ST with torque wrenc
Page 97 and 98: 3. ENGINE BRAKE OPERATION Engine br
Page 99 and 100: 3. EVALUATION Stall speed (at sea l
Page 101 and 102: 2. TEST METHODS 1) Temporarily atta
Page 103 and 104: 12. Overall Transmission A: SECTION
Page 105 and 106: 10) Remove the oil cooler inlet and
Page 107 and 108: 6) Remove the oil pan. NOTE: Use a
Page 109 and 110: 19) Take out the thrust needle bear
Page 111 and 112: 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
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9) Install the one-way clutch inner
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4) Install ST to low clutch drum. S
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15) Install rear sun gear. NOTE: Pa
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4) Measurement of backlash (Selecti
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6) Using ST1 and ST2, install snap
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23. Transmission Control Module (TC
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3-3 [C100] COMPONENT PARTS 1. Manua
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3-3 [W1A0] SERVICE PROCEDURE 1. Man
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3-3 [W1E0] SERVICE PROCEDURE 1. Man
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3-3 [W2C0] SERVICE PROCEDURE 2. Aut
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3-4 [S1A0] SPECIFICATIONS AND SERVI
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3-4 [S2C1] SPECIFICATIONS AND SERVI
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3-4 [S2C3] SPECIFICATIONS AND SERVI
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3-4 [C2A0] COMPONENT PARTS 2. Rear
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3-4 [C2B2] COMPONENT PARTS 2. Rear
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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
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3-4 [W2B0] SERVICE PROCEDURE 2. Rea
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3-4 [W2C0] SERVICE PROCEDURE 2. Rea
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3-4 [W2E0] SERVICE PROCEDURE 2. Rea
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3-4 [W3B0] SERVICE PROCEDURE 3. Rea
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3-4 [W3D0] SERVICE PROCEDURE 3. Rea
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3-4 [K100] DIAGNOSTICS 1. Propeller
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