DISASSEMBLY AND REASSEMBLY







Disassembly steps

>>E<<
1.
Oil seal

>>D<<
2.
Oil seal


3.
Filler plug


4.
Gasket


5.
Drain plug


6.
Gasket

>>C<<
7.
Transmission case

>>B<<
8.
Dowel pin


9.
Magnet holder


10.
Magnet
<<A>>
>>A<<
11.
Input shaft assembly


12.
Spacer
<<A>>
>>A<<
13.
Output gear assembly


14.
Spacer
<<A>>
>>A<<
15.
Differential assembly


16.
Spacer


17.
Transmission oil guide

>>A<<
18.
Motor housing

DISASSEMBLY SERVICE POINT



<<A>> INPUT SHAFT ASSEMBLY / OUTPUT GEAR ASSEMBLY / DIFFERENTIAL ASSEMBLY REMOVAL


Remove the input shaft assembly and the output gear assembly together with the differential assembly.

ADJUSTMENT BEFORE INSTALLATION



SELECTION OF SPACER FOR ADJUSTING INPUT SHAFT BEARING AXIAL PLAY



1.Measure distance "A" between the motor housing mounting surface and the spacer inserting surface in the motor housing.
2.Install the input shaft assembly to the transmission case, and measure distance "B" between the transmission case mounting surface and the bearing end on the input shaft assembly.
3.Use the following expression to calculate the amount of axial play.
(1) Amount of axial play = A - B
4.From the amount of axial play calculated in the 3, select the spacer having adequate dimension.
Amount of axial play mm
Spacer mm
1.28 - 1.37
1.22
1.37 - 1.46
1.31
1.46 - 1.55
1.40
1.55 - 1.64
1.49
Standard value: 0.03 - 0.18 mm
(Input shaft bearing axial play)

SELECTION OF SPACER FOR ADJUSTING OUTPUT SHAFT BEARING AXIAL PLAY



1.Measure distance "A" between the motor housing mounting surface and the spacer inserting surface in the motor housing.
2.Install the output gear assembly to the transmission case, and measure distance "B" between the transmission case mounting surface and the bearing end on the output gear assembly.
3.Use the following expression to calculate the amount of axial play.
(1) Amount of axial play = A - B
4.From the amount of axial play calculated in the 3, select the spacer having adequate dimension.
Amount of axial play mm
Spacer mm
1.19 - 1.28
1.13
1.28 - 1.37
1.22
1.37 - 1.46
1.31
1.46 - 1.55
1.40
1.55 - 1.64
1.49
Standard value: 0.03 - 0.18 mm
(Out put gear bearing axial play)

SELECTION OF SPACER FOR ADJUSTING DIFFERENTIAL BEARING AXIAL PLAY



1.Measure distance "A" between the motor housing mounting surface and the spacer inserting surface in the motor housing.
2.Install the differential assembly to the transmission case, and measure distance "B" between the transmission case mounting surface and the bearing end on the differential assembly.
3.Use the following expression to calculate the amount of axial play.
(1) Amount of axial play = A - B
4.From the amount of axial play calculated in the 3, select the spacer having adequate dimension.
Amount of axial play mm
Spacer mm
0.92 - 1.01
0.86
1.01 - 1.10
0.95
1.10 - 1.19
1.04
1.19 - 1.28
1.13
1.28 - 1.37
1.22
Standard value: 0.05 - 0.17 mm
(Differential bearing axial play)

MEASURING INPUT SHAFT TORQUE


The input shaft torque must be measured before assembling the components. To do so, temporarily assemble the differential assembly, the output gear assembly and the input shaft assembly together with the motor housing into the transmission case.
1.Install the output gear assembly together with the differential assembly.
2.Slightly lift the output gear assembly from the transmission case to install the input shaft assembly.
3.Install the motor housing to the transmission case.
note This is only the temporary installation to measure the input axis torque. It is not necessary to apply the sealant.
4.Tighten the motor housing mounting bolt to the specified torque of 24 ± 3 N·m.
5.By hand, rotate the input shaft assembly approximately 10 times.

6.To measure the input shaft torque, wrap vinyl tape around the end of a deep socket (outer diameter: approx. 17 mm).
7.Insert the socket into the input shaft splined hole and make sure that it does not slip in radial direction.

8.Assemble a small torque wrench into the socket, and then measure the input shaft torque.
Standard value: 0 - 10 N·cm
9.If the input axis torque is different from the standard value, select and measure the spacer again.

REASSEMBLY SERVICE POINT



>>A<< INPUT SHAFT ASSEMBLY / OUTPUT GEAR ASSEMBLY / DIFFERENTIAL ASSEMBLY INSTALLATION


1.Install the output gear assembly together with the differential assembly.
2.Slightly lift the output gear assembly from the transmission case to install the input shaft assembly.

>>B<< DOWEL PIN INSTALLATION



Drive in two dowel pins into the transmission case until the shown dimension is satisfied.

>>C<< MOTOR HOUSING INSTALLATION


1.Select and install the spacer to the motor housing. (ADJUSTMENT BEFORE INSTALLATION - SELECTING SPACER FOR ADJUSTING EACH AXIAL PLAY

2.
caution
  • Evenly apply the sealant not too small or not too much.
  • Thoroughly remove foreign materials such as water, oil and sealant from the surface where the sealant is applied. Never touch the degreasing surface with a finger.
Apply approximately 1.5 mm bead of sealant, as shown in the illustration, to the surface where the transmission case motor housing is installed.
SEALANT
Brand name: Three bond 1216 or equivalent
3.Install the motor housing to the transmission case.
4.Tighten the motor housing mounting bolt to the specified torque of 24 ± 3 N·m.

>>D<< OIL SEAL LH INSTALLATION



1.Use the special tool oil seal installer (MD998800) to install the transmission oil seal LH to the transmission case.
2.Apply ATF to the oil seal LH lip.

>>E<< OIL SEAL RH INSTALLATION



1.Use the special tool oil seal installer (MD998800) to install the transmission oil seal RH to the motor housing.
2.Apply ATF to the oil seal RH lip.