<< A >> SNAP RING REMOVAL
Using a flat blade screwdriver etc., remove the snap ring from the forward clutch drum.
Scheme 101
<< B >> INTERNAL GEAR REMOVAL
Remove the internal gear from the forward clutch drum.
Scheme 102
<< C >> SNAP RING REMOVAL
Using a flat blade screwdriver etc., remove the snap ring from the forward clutch drum.
Scheme 103
<< D >> SNAP RING REMOVAL
Remove the snap ring using snap ring pliers, and remove the input shaft from the forward clutch drum.
Scheme 104
<< E >> SEAL RING REMOVAL
Remove the seal rings (small and big) from the input shaft.
Scheme 105
>> A << SEAL RING INSTALLATION
| CAUTION | Apply Vaseline when installing the seal rings. Do not re-use the seal rings. |
Install the seal rings (small and big) on the input shaft.
>> B << SNAP RING INSTALLATION
| CAUTION | Be careful not to strain the snap ring by expanding it excessively. Do not re-use the snap ring. |
Install the input shaft on the forward clutch drum, and attach the snap ring.
>> C << SNAP RING INSTALLATION
| CAUTION | Do not re-use the snap ring. |
Install the snap ring on the forward clutch drum.
>> D << INTERNAL GEAR INSTALLATION
Install the internal gear on the forward clutch drum.
>> E << SNAP RING INSTALLATION
| CAUTION | Do not re-use the snap ring. |
Install the snap ring on the forward clutch drum.
<< A >> NUT REMOVAL
Remove the nut from the reduction gear sub-assembly.
Scheme 106
<< B >> REDUCTION GEAR BEARING REMOVAL
| CAUTION | Align the tang of special tool as shown in the illustration. |
Scheme 107
Scheme 108
Using the special tools MB990810, MB990947 and MD999566, remove the inner race of reduction gear bearing (converter housing side) from the reduction gear sub-assembly.
<< C >> REDUCTION GEAR BEARING REMOVAL
Using the special tools MB990984 and MD998917, remove the outer race of reduction gear bearing (transaxle case side) from the reduction gear sub-assembly.
Scheme 109
>> A << REDUCTION GEAR BEARING INSTALLATION
| CAUTION | Do not re-use the inner race. Replace the inner race together with the outer race. |
Using the special tools MD998812, MD998813 and MD998819, install the inner race of reduction gear bearing (transaxle case side) on the reduction gear sub-assembly.
Scheme 110
>> B << REDUCTION GEAR BEARING INSTALLATION
| CAUTION | Do not re-use the inner race. Replace the inner race together with the outer race. |
Using the special tools MD998812, MD998813 and MD998819, install the inner race of reduction gear bearing (converter housing side) on the reduction gear sub-assembly.
Scheme 111
>> C << NUT INSTALLATION
Install the nut on the reduction gear sub-assembly to the specified torque.
Tightening torque: 250 N.m (184 ft-lb)
Scheme 112
>> A << REDUCTION PINION GEAR/IDLER GEAR INSTALLATION
| CAUTION | When attaching the idler gear to the reduction pinion gear, make sure the center boss portion A faces the reduction pinion gear. |
| Center boss portion A | Long |
|---|---|
| Center boss portion B | Short |
CENTER BOSS REFERENCE
Using the special tools MD998812, MD998813 and MD998819, attach the idler gear to the reduction pinion gear.
Scheme 113
Scheme 114
Scheme 115
Required special tools
- MB990810: Side bearing puller
- MB991452: Oil seal installer
- MD998812: Installer cap
- MD998813: Installer-100
- MD998823: Installer adapter (48)
- MB992138: Bearing Installer
<< A >> DIFFERENTIAL SIDE BEARING REMOVAL
Using the special tool MB990810, remove the inner race of differential side bearing (transaxle case side) from the differential sub-assembly.
Scheme 116
<< B >> DIFFERENTIAL SIDE BEARING REMOVAL
Using the special tools MB990810 and MB991452 < W1CJA >, remove the inner race of differential side bearing (converter housing side) from the differential sub-assembly.
Scheme 117
Scheme 118
>> A << DIFFERENTIAL SIDE BEARING INSTALLATION
| CAUTION | Do not re-use the inner race. Replace the inner race together with the outer race. |
Using the special tool MD998812, MD998813 and MD998823 < F1CJA > or MB992138 < W1CJA >, install the inner race of reduction gear bearing (converter housing side) on the reduction gear sub-assembly.
Scheme 119
Scheme 120
| CAUTION | Do not re-use the inner race. Replace the inner race together with the outer race. |
Using the special tools MD998812, MD998813 and MD998823, install the inner race of reduction gear bearing (transaxle case side) on the reduction gear sub-assembly.
Scheme 121
>> A << DIFFERENTIAL CASE/FINAL GEAR INSTALLATION
| CAUTION | When attaching the final gear to the differential case, make sure the side with the bigger distance from the edge to the flange A face the differential case. |
| Distance from gear edge to flange A | Long |
|---|---|
| Distance from gear edge to flange B | Short |
GEAR EDGE TO FLANGE DISTANCE
Scheme 122
Install the final gear on the differential case, and tighten the fastening bolts to the specified torque.
Tightening torque: 130 N.m (96 ft-lb)
Scheme 123
Scheme 124
Required special tools
- MD998812: Installer cap
- MB992154: Oil seal installer
- MB992075: Handle
- MB992142: Oil seal installer
- MB990936: Installer adapter
Scheme 125
- Apply a 1.5 mm diameter bead of sealant as illustrated onto the cover. 3M™ATD Part No. 8660 or equivalent
- Attach the cover to the transfer and tighten it to the specified torque. Tightening torque: 12 ± 2 N.m (106 ± 18 in-lb)
>> B << OIL SEAL INSTALLATION
| CAUTION | Pay attention to the transfer case that can possibly twist when the pin projection is too large. |
Scheme 126
Scheme 127
Scheme 128
- Adjust the projection allowances of the two pins of the special tool, Oil Seal Installer (MB992154) to be 0.2 ± 0.1 mm (0.007 ± 0.003 in). NOTE: The two pins are inserted into the special tool, Oil Seal Installer (MB992154). When the oil seal is replaced, the traces are found on the transfer case so that the replacement using the specified special tool can be recognized.
- Apply specified grease to the oil seal lip area. Specified grease: Retinax A
- Using the special tool MD998812 and MB992154, install the oil seal.
- Check whether the two traces are found on the transfer case.
Scheme 129
- Using the special tool MB992075 and MB992142, install the oil seal.
- Apply specified grease to the oil seal lip area. Specified grease: Retinax A
Scheme 130
- Using the special tool MB990936, install the oil seal.
- Apply transfer oil to the lip of oil seal.