Diesel Data: Automotive Repair
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Part 2

COUNTERSHAFT



DISASSEMBLY / INSPECTION / REASSEMBLY





NOTE:
- Lubricate all parts with Automatic Transmission Fluid (ATF) before reassembly.
- Inspect the thrust needle bearings and the needle bearings for galling and rough movement.
- Before installing the O-rings, wrap the shaft splines with tape to prevent damaging the O-rings.
- Locknut has left-hand threads.

DISASSEMBLY / REASSEMBLY





1. Using a hydraulic press, press out the countershaft while supporting.4th gear.

NOTE: Place an attachment between the press and the countershaft to prevent damage to the shaft.

CAUTION: Do not allow the countershaft to fall and hit the ground when pressed clear.





2. Assemble the parts on the countershaft as shown.

NOTE:
- Lubricate all parts with Automatic Transmission Fluid (ATF) during assembly.
- Before installing the O-rings, wrap the shaft splines with tape to prevent damaging the O-rings.





3. Install the reverse selector hub on the countershaft sub-assembly, and then press the reverse selector hub using the special tool and a press as shown.

INSPECTION
- Clearance Measurement

NOTE: Lubricate all parts with Automatic Transmission Fluid (ATF) during assembly.

1. Remove the countershaft bearing from the transmission housing.





2. Install the parts on the countershaft using the special tool and a press.

NOTE: Do not assemble the O-rings during inspection.





3. Install the parts on the countershaft subassembly, then torque the locknut to 29 Nm (22 ft. lbs.)

NOTE: Countershaft locknut has left-hand threads.





4. Measure the clearance between the 2nd gear and the 28 mm distance collar with a feeler gauge.

NOTE: Take measurements in at least three places, and use the average as the actual clearance.

5. If the clearance is out of tolerance, remove the 28 mm distance collar and measure the width.





6. Select and install a new distance collar, then recheck.
7. After selecting a new distance collar, recheck the clearance and make sure it is within tolerance.

ONE-WAY CLUTCH



DISASSEMBLY / INSPECTION / REASSEMBLY





1. Separate countershaft 1st gear from the park gear by turning the park gear in the direction shown.





2. Remove the one-way clutch by prying it up with the end of a screwdriver.





3. Inspect the parts as follows:





4. After the parts are assembled, hold countershaft 1st gear and turn the park gear in the direction shown to be sure it turns freely, Also make sure the park gear does not turn in the opposite direction.

CLUTCH










Illustrated Index (A4RA, B4RA Transmission)








Illustrated Index (A4RA, B4RA Transmission)

DISASSEMBLY





1. Remove the snap ring, then remove the clutch end plate, clutch discs and plates.





2. Remove the disc spring.

NOTE: Except 2nd clutch.





3. Install the special tools as shown.





CAUTION: If either and of the special tool is set over an area of the spring retainer which is unsupported by the return spring, the retainer may be damaged. Be sure the special tool is adjusted to have full contact with the spring retainer.





4. Compress the return spring.





5. Remove the snap ring. Then remove the special tools, spring retainer and return spring.





6. Wrap a shop rag around the clutch drum, and apply air pressure to the Automatic Transmission Fluid (ATF) passage to remove the piston.
Place a finger tip on the other end while applying air pressure.

REASSEMBLY

NOTE:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry them with compressed air.
- Blow out all passages.
- Lubricate all parts with Automatic Transmission Fluid (ATF) before reassembly.





1. Inspect the check valve; if it's loose, replace the piston.





2. Install new O-rings on the clutch piston.





3. Install the piston in the clutch drum. Apply pressure and rotate to ensure proper seating.

NOTE: Lubricate the piston O-ring with ATF before installing.

CAUTION: Do not pinch the O-ring by installing the piston with too much force.





4. Install the return spring and spring retainer, and position the snap ring on the retainer.





5. Install the special tools as shown.





CAUTION: If either end of the special tool is set over an area of the spring retainer which is unsupported by the return spring, the retainer may be damaged. Be sure the special tool is adjusted to have full contact with the spring retainer.





6. Compress the return spring.





7. Install the snap ring.
8. Remove the special tools.





9. Install the disc spring.

NOTE: Install the disc spring in the direction shown, except 2nd clutch.

10. Soak the clutch discs thoroughly in ATF for a minimum of 30 minutes.





11. Starting with a clutch plate, alternately install the clutch plates and discs. Install the clutch end plate with flat side toward the disc.

NOTE: Before installing the plates and discs, make sure the inside of the clutch drum is free of dirt or other foreign matter.





12. Install the snap ring.





13. Measure the clearance between the clutch end plate and top disc with a dial indicator. Zero the dial indicator with the clutch end plate lowered and lift it up to the snap ring. The distance that the clutch end plate moves is the clearance between the clutch end plate and top disc.

NOTE: Take measurements in at least three places, and use the average as the actual clearance.





14. If the clearance is not within the service limits, select a new clutch end plate from the following table.

NOTE: If the thickest clutch end plate is installed, but the clearance is still over the standard, replace the clutch discs and clutch plates.





CLUTCH END PLATE

15. After replacing the clutch end plate, make sure that the clearance is within tolerance.

DIFFERENTIAL







Illustrated Index

BACKLASH INSPECTION





1. Place differential assembly on V-blocks and install both axles.
2. Check backlash of both pinion gears.

Standard (New): 0.05 - 0.15 mm (0.002 - 0.006 inch)

3. If backlash is out of tolerance, replace the differential carrier.

BEARING REPLACEMENT

NOTE: Check bearings for wear and rough rotation. If bearings are OK, removal is not necessary.





1. Remove bearings using a bearing puller.





2. Install new bearings using the special tool as shown.

DIFFERENTIAL CARRIER REPLACEMENT
1. Remove the final driven gear from the differential carrier.

NOTE: The final driven gear bolts have left-hand threads.





2. Pry the snap ring off differential carrier, then remove the speedometer drive gear and 5 x 10 mm roller.





3. Install the 5 x 10 mm roller in the differential carrier.
4. Install the speedometer drive gear with its chamfered side facing the carrier. Align the cutout on the bore of the speedometer drive gear with the 5 x 10 mm roller.





5. Align the hooked end of the snap ring with the pinion shaft as shown, then install the snap ring in the differential carrier groove.





6. Install the final driven gear, then tighten the bolts to the specified torque.

TORQUE: 101 Nm (7" ft. lbs.)

NOTE: The final driven gear bolts have left-hand threads.

7. Install a new ball bearing.

OIL SEAL REMOVAL
1. Remove the differential assembly.





2. Remove the oil seal from the transmission housing.





3. Remove the oil seal from the torque converter housing.






























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