GROUP 3 DISASSEMBLY AND ASSEMBLY

1.TRANSMISSION
1) DISASSEMBLY
Η Transmission assembly set.

20D7TM001

Θ Disconnect torque converter.

20D7TM002

Ι Extract PTO shaft.

20D7TM003

Κ Remove control valve bolt.

20D7TM004

3-25
Λ Extract control valve.

20D7TM005

20D7TM006

Μ Extract oil filter.

20D7TM007

Ν Remove snap ring.

20D7TM008

Ξ Remove parking lever.

20D7TM009

3-26
Ο Remove snap ring.

20D7TM010

Π Remove bolt.

20D7TM011

Ρ Remove out wheel bolt.

20D7TM012

΢ Remove bolt on the back side of filter.

20D7TM013

Σ Remove bolt.

20D7TM014

3-27
⯾ Connect disassembly bolt.

20D7TM015

⯿ Disassemble torque converter housing.

20D7TM016

⬼ Disassemble spacer.

20D7TM017

⬽ After disassemble.

20D7TM018

⬾ Disassemble output gear assembly set.

20D7TM019

3-28
⬿ Disassemble connection.

20D7TM020

⭀ Extract band brake.

20D7TM021

⭁ Disassemble forward clutch gear.

20D7TM022

⭂ Disassemble reverse clutch gear.

20D7TM023

⭃ After disassemble.

20D7TM024

3-29
2) ASSEMBLY
(1) Assembly of transmission case outside part
Plug assembly
ö Before assemble taper plug, spread loctite #577.
Η Assemble the upper part taper plug of hydraulic pipe.

20D7TM025

Θ Assemble installation part taper plug of control valve.

20D7TM026

Ι Assemble space installation part.

20D7TM027

Κ Assemble the left taper plug.

20D7TM028

3-30
Λ Confirm torque.
ÂTightening torque : 3.5~4.5 kgfÂm
(25~33 lbfÂft)

20D7TM029

Oil seal pressurizer of cam shaft

Η Spread sealant on oil seal.
ö Spread loctite #592 on the out wheel of oil seal.
Spread grease on inside wheel of oil seal.

20D7TM030

Θ Pressurize oil seal.

20D7TM031

Assembly of filter assembly bolt

Η Spread sealant on oil seal.
ö Spread loctite #277 on filter assembly bolt.

20D7TM032

Θ Confirm assembly and torque.

ÂTightening torque : 3.5~4.5 kgfÂm
(25~33 lbfÂft)

20D7TM033

3-31
 (2) Assembly of transmission case inside
Assembly of bearing and parking control shaft
Η Pressurize R part of bearing out wheel.
ö R part : Installation part of reverse clutch gear.

20D7TM034

Θ Pressurize O part of bearing out wheel.

ö O part : Installation part of output gear assembly.

20D7TM035

Ι Pressurize F part of bearing out wheel.

ö F part : Installation part of forward clutch gear.

20D7TM036

Κ Assemble adjustment shaft.

20D7TM037

3-32
Λ Assemble nut.

20D7TM038

Μ Spread grease on bearing out wheel.

ö When installing taper roller bearing, make sure
whether or not it is close.
ö Spread grease in taper roller bearing.

20D7TM039

Assembly of forward / reverse clutch pack

Η Confirm seal ring of reverse clutch.
ö Spread grease on seal ring of clutch pack.

20D7TM040

Θ Spread oil on seal ring of reverse clutch.

20D7TM041

Ι Assemble reverse clutch at transmission.

20D7TM042

3-33
Κ Confirm seal ring of forward clutch.

20D7TM043

Λ Spread oil on seal ring of forward clutch.

20D7TM044

Μ Assemble forward clutch at transmission.

ö After finishing assembly, make sure whether or not
revolution of forward/reverse clutch pack is good.

20D7TM045

Assembly of parking brake system

Η Fix small connection in PBB.

20D7TM046

Θ Set in parking drum.

20D7TM047

3-34
Ι Spread grease on cam shaft.

20D7TM048

Κ Fix large connection in cam shaft.

20D7TM049

Λ Fit large connection in PBB.

20D7TM050

Μ Assemble an eccentric shaft in PBB.

20D7TM051

Assembly of output gear assembly

Η Assembly output gear.

20D7TM052

3-35
Θ Confirm gear revolution condition.

20D7TM053

(3) Assembly of spacer sub assembly

Assembly of oil pump
Η Assemble O-ring of charging pump.
ö Spread grease at O-ring surface.

20D7TM054

Θ Spread sealant on charging pump.

ö Spread loctite #5127 at stator shaft lower in oil pump.

20D7TM055

Ι Spread sealant on the whole surface.

20D7TM056

Κ Fix charging pump in spacer.

20D7TM057

3-36
Λ Spread sealant on hexagon bolt.
ö Spread loctite #242 at bolt.

20D7TM058

Μ Confirm assembly and torque.

ÂTightening torque : 3.5~4.0 kgfÂm
(25~29 lbfÂft)

20D7TM059

Assembly of inlet and outlet of pressure adjustment

valve in torque converter and pressure checking port
Η Fix steel ball in spacer.

20D7TM060

Θ Fix spring.

20D7TM061

Ι Spread sealant on plug and O-ring.

ö Spread loctite #277 at plug and bolt.

20D7TM062

3-37
Κ Confirm torque.
ÂTightening torque : 3.5~4.5 kgfÂm
(25~33 lbfÂft)

20D7TM063

Λ Spread sealant on hex bolt.

20D7TM064

Μ Confirm torque.
ÂTightening torque : 3.5~4.5 kgfÂm
(25~33 lbfÂft)

20D7TM065

Assembly of bearing cup

ö After measuring the transmission case, spacer and
each clutch pack and estimating a proper amount of
shim.
Insert a proper amount of shim before assembling
bearing cup.
Make sure whether or not it is close with the lower of
bearing cup.
20D7TM066
Η Pressurize F part of bearing out wheel.

Θ Pressurize R part of bearing out wheel.

20D7TM067

3-38
Ι Pressurize O part of bearing out wheel.

20D7TM068

(4) Assembly of torque converter housing sub assembly

Assembly of temperature sensor and O-ring
Η Spread loctite #577 on temperature sensor.

20D7TM069

Θ Confirm assembly and torque.

ÂTightening torque : 3.0~4.0 kgfÂm
(22~29 lbfÂft)

20D7TM070

Ι Assemble O-ring and spread grease.

20D7TM071

Oil strainer assembly

Η Fix spring in strainer.

20D7TM072

3-39
Θ Fix strainer in torque converter housing.

20D7TM073

Ι Temporarily assemble plug.

20D7TM074

Κ Confirm torque.
ÂTightening torque : 8~10 kgfÂm
(58~72 lbfÂft)

20D7TM075

(5) Assembly of sub assembly

Assembly of transmission case and spacer sub assembly
Η Spread oil.

20D7TM076

Θ Fix O-ring.

20D7TM077

3-40
Ι Spread loctite #5127 on transmission case.

20D7TM078

Κ Pressurize lock pin.

20D7TM079

Λ Assemble space.

20D7TM080

Μ Confirm gear revolution condition.

20D7TM081

Torque converter assembly

Η Spread loctite #5127 on space.

20D7TM082

3-41
Θ Work roller.
ö Pay attention to tear O-ring of torque converter and oil
pump.

20D7TM083

Ι Fit torque converter housing in space.

20D7TM084

Κ Spread loctite #277 on bolt.

20D7TM085

Λ Temporarily assemble bolt.

20D7TM086

Μ Confirm torque.
ÂTightening torque : 5.5~6.5 kgfÂm
(40~47 lbfÂft)

20D7TM087

3-42
 (6) Transmission outside assembly
Fastening of transmission case bolt
Η Revolve 90¡£
.

20D7TM088

Θ Spread sealant on socket bolt.

20D7TM089

Ι Temporarily assemble at transmission case.

20D7TM090

Κ Confirm torque.

20D7TM091

Λ Spread sealant on hexagon bolt.

ö Spread loctite #277 on bolt.

20D7TM092

3-43
Μ Confirm torque.
ÂTightening torque : 5.5~6.5 kgfÂm
(40~47 lbfÂft)

20D7TM093

Oil filter assembly

Η Temporarily assemble filter.

20D7TM094

Θ Confirm fastening.
ÂTightening torque : 0.8~1.2 kgfÂm
(5.8~8.7 lbfÂft)

20D7TM095

Parking brake part assembly

Η Assemble snap ring.

20D7TM096

Θ Spread loctite #277 on support pin.

20D7TM097

3-44
Ι Temporarily assemble support pin.

20D7TM098

Κ Confirm torque.
ÂTightening torque : 2.0~3.0 kgfÂm
(14~22 lbfÂft)

20D7TM099

Λ Fix parking lever.

20D7TM100

Μ Assemble snap ring.

20D7TM101

Ν Fix spring and spread loctite #277 on bolt.

20D7TM102

3-45
Ξ Temporarily assemble parking bracket.

20D7TM103

Ο Confirm torque.
ÂTightening torque : 0.6~0.8 kgfÂm
(4.3~5.8 lbfÂft)

20D7TM104

The way to adjusting parking brake

Η Tighten the adjustment shaft and loosen the shaft a 3/4 revolution.
ÂTightening torque : 0.65kgfÂm (4.7lbfÂft)
Θ Tighten the nut.
ÂTightening torque : 3kgfÂm (221lbfÂft)

Spread loctite #592 Position eccentric shaft

as figure

Nut

Adjustment shaft

20D7PT33

Pipe offering oil path of reverse clutch assembly

Η Prepare reverse pipe.

20D7TM105

3-46
Θ Spread loctite #577 on nipple plug.

20D7TM106

Ι Temporarily assemble oil pressure pipe and seal

washer at the same time.

20D7TM107

Κ Spread sealant on nipple plug.

20D7TM108

Λ Temporarily assemble oil pressure pipe and seal

washer at the same time.

20D7TM109

Μ Confirm torque.
ÂTightening torque : 3.5~4.0 kgfÂm
(25~29 lbfÂft)

20D7TM110

3-47
 Oil seal output gear assembly
Η Spread loctite #592 on the out wheel of oil seal.

20D7TM111

Θ Pressurize oil seal.

20D7TM112

Ι Spread grease on inside wheel of oil seal.

20D7TM113

Control valve assembly

Η As assembling, use guide pin at two spot.
Fix guide pin.

20D7TM114

Θ Assemble control valve assembly.

20D7TM115

3-48
Ι Assemble hex bolt and confirm torque.
ÂTightening torque : 3~4 kgfÂm
(22~29 lbfÂft)

20D7TM116

Air breather and oil level gauge guide pipe assembly

Η Assemble air breather.
Air breather
ö Spread loctite #577 on air breather.

20D7TM117

Θ Spread sealant on oil level gauge guide.

ö Spread loctite #608 on pipe.

20D7TM118

Ι Pressurize guide.

20D7TM119

3-49
2. DRIVE AXLE
1) DISASSEMBLY
Η Drive axle.

20D7AXLE001

Θ Remove the bolt of axle shaft.

20D7AXLE002

Ι Extract the left axle shaft.

20D7AXLE003

Κ Extract the right axle shaft.

20D7AXLE004

3-50
Λ Remove the bolt of plate / nut.

20D7AXLE005

Μ Extract the nut.

20D7AXLE006

Ν Extract the plate.

20D7AXLE007

Ξ Extract the hub bearing.

20D7AXLE008

Ο Extract the hub.

20D7AXLE009

3-51
Π Remove the bolt of flange shaft.

20D7AXLE010

Ρ Extract the flange shaft.

20D7AXLE011

΢ Disassemble the piston brake.

20D7AXLE012

Σ Disassemble the carrier assembly.

20D7AXLE013

Τ Fix the carrier assembly.

20D7AXLE014

3-52
⯿ Remove the bolt of carrier cap.

20D7AXLE015

⬼ Extract the carrier cap.

20D7AXLE016

⬽ Remove the left adjusting cap of bearing cup.

20D7AXLE017

⬾ Remove the right adjusting cap of bearing cup.

20D7AXLE018

⬿ Disassemble the differential assembly.

20D7AXLE019

3-53
⭀ After disassemble the carrier.

20D7AXLE020

2) ASSEMBLY
(1) Assembly of carrier assembly
Differential device assembly
⯱ Assemble spider and the differential pinion.

20D7AXLE021

⯲ Assemble the washer and the differential gear.

20D7AXLE022

⯳ Assemble the spider and the differential.

20D7AXLE023

3-54
Κ Assemble the washer and the differential gear.

20D7AXLE024

Λ Assemble the differential case.

20D7AXLE025

Μ Fix the bolt.

20D7AXLE026

Ν Confirm the differential gear backlash.

ö Adjust backlash of differential gear within 0.015mm.

20D7AXLE027

Ξ Assemble the ring gear.

20D7AXLE028

3-55
Ο Assemble the bearing of differential.

20D7AXLE029

(2) Assembly of carrier sub assembly

Adjusting shim and pinion shaft assembly
Η Fix the carrier case.

20D7AXLE030

Θ Measure a gap(A) for deciding an amount of shim

with feeler gauge.
ö Determine shim X.
ÂX = AÜMounting distance (MD) of pinion gear
Ex 1) A = 0.5, MD value = - 0.2
X = 0.5 + 0.2 = 0.7mm
Ex 2) A = 0.5, MD value = + 0.2 20D7AXLE031
X = 0.5 - 0.2 = 0.3mm

Ι Select the shim and assemble.

20D7AXLE032

Κ Pressurize the bearing cup.

20D7AXLE033

3-56
Λ Pressurize the bearing cone into the pinion shaft.

20D7AXLE034

Μ Fix the pinion shaft.

20D7AXLE035

Ν Set the ball.

20D7AXLE036

Ξ Fix the fixing jig.

20D7AXLE037

Ο Fix the ball.

20D7AXLE038

3-57
Π Revolve the carrier case in 180Á.

20D7AXLE039

Ρ Fix the spacer.

20D7AXLE040

΢ Shim measuring gauge 1 insert.

20D7AXLE041

Σ Shim measuring gauge 2 insert.

20D7AXLE042

Τ Put the shim measuring block.

20D7AXLE043

3-58
⯿ Measure a gap (B).
⚰ Determine shim X.
♼X = B - End play (0.03~0.06)
Ex 1) B = 0.5,
X = 0.5 - (0.03~0.06) = 0.47~0.44mm

20D7AXLE044

⬼ Remove the pinion shaft.

20D7AXLE045

⬽ Assemble the bearing cup.

20D7AXLE046

⬾ Assemble and fit the pinion.

20D7AXLE047

⬿ Assemble the shim.

20D7AXLE048

3-59
⭀ Fix the bearing cone.

20D7AXLE049

Assembly of carrier sub assembly

⯱ Pressurize the oil seal.

20D7AXLE050

⯲ Fix the U-joint flange.

⚰ Assemble U-joint flange in preload 0.01~0.19 kgf♼m.

20D7AXLE051

⯳ Fix the O-ring.

20D7AXLE052

⯴ Temporarily assemble the nut.

⚰ Spread loctite #242 on nut.

20D7AXLE053

3-60
Λ Fasten the torque.
ÂTightening torque : 16.2~19.1 kgfÂm
(117~138 lbfÂft)

20D7AXLE054

Μ Confirm the preload.

20D7AXLE055

Ν Perform the calking.

Calking
40

20D7PT34

Ξ Assemble the differential sub in case.

20D7AXLE057

Ο Fix the steel ball.

Paint marking(Both sides)

20D7PT35

3-61
Π Temporarily assemble the carrier cap.

20D7AXLE059

Ρ Fasten the torque.

ö Spread loctite #277 on bolt.
ÂTightening torque : 26.8~32 kgfÂm
(194~231 lbfÂft)

20D7AXLE060

Adjust backlash
Η Assemble the RING BRG ADJUST.

20D7AXLE062

Θ Adjust the RING BRG ADJUST.

20D7AXLE063

Ι Measure backlash.

20D7AXLE064

3-62
Κ Fasten RING BRG ADJUST.

20D7AXLE065

Λ Measure backlash again.

ö Bachlash of pinion shaft and ring gear is 0.15~0.2mm
(0.006~0.008 in)
ö If backlash is wrong, carry out adjusting work.
Adjust the left / right of RING BRG ADJUST by one
and one clip.
20D7AXLE066

Μ Fit position.

20D7AXLE067

Ν Assemble cotter pin.

Paint marking(Both sides)

20D7PT35

ö After assembling, adjust pattern of the gear and Drive side(Forward) Coast side (Reverse)

pinion shaft as figure. 60

% 60
%
Heel Heel
If pattern is not adjusted, take a measure as 40% 40
%
measuring backlash again and then reassemble.
75%

40
40~

~7
5%

Toe Toe
20D7PT37

3-63
 Assembly of carrier assembly
Η Pressurize lock pin into drive axle.

20D7AXLE069

Θ Spread sealant on the installation surface of carrier.

20D7AXLE070

Ι Fix assembly guide bar.

20D7AXLE071

Κ Fit carrier at drive axle housing.

ö Spread loctite #5127 on drive axle housing.

20D7AXLE072

Λ Spread loctite #277 on the spring washer bolt.

20D7AXLE073

3-64
Μ Temporarily assemble bolt and confirm torque.
ÂTightening torque : 6~7 kgfÂm
(43~51 lbfÂft)

20D7AXLE074

(2) TRAVELING BRAKE SYSTEM ASSEMBLY

Piston assembly
Η Fix large quad ring into brake.

20D7AXLE075

Θ Fix small quad ring into brake.

ö When assembling quad ring, pay attent to chopping.

20D7AXLE076

Ι Spread oil on the piston.

20D7AXLE077

Κ Fix piston into drive axle housing.

20D7AXLE078

3-65
Λ Set assembly jig.

20D7AXLE079

Μ Assemble close to drive axle housing.

20D7AXLE080

Ν Pressurize lock pin.

20D7AXLE081

Ξ Measure projection degree of piston.

ö Manage projection degree of piston in 0.6~0.9mm.

20D7AXLE082

Friction plate and plate assembly

Η Pressurize oil seal into flange.

20D7AXLE083

3-66
Θ Assemble snap ring at socket.

20D7AXLE084

Ι Fix socket gear into flange shaft.

20D7AXLE085

Κ Fix plate into socket gear.

20D7AXLE086

Λ Fix friction plate into socket gear.

20D7AXLE087

Μ Fix friction plate and confirm the direction.

20D7AXLE088

3-67
Ν Assemble snap ring at socket.

20D7AXLE089

Ξ Measure stepped pulley between flange and plate

and record.
ö Manage stepped pulley of flange 0.6~0.9mm.

20D7AXLE090

Flange shaft assembly

Η Select flange shaft.

20D7AXLE091

Θ Spread loctite # 5127.

20D7AXLE092

Ι Spread on the whole surface of flange shaft.

20D7AXLE093

3-68
Κ Fit flange into drive axle housing.

20D7AXLE094

Λ Spread loctite #242 on bolt.

20D7AXLE095

Μ Fasten bolt.
ÂTightening torque : 9~11.5 kgfÂm
(65~83 lbfÂft)

20D7AXLE096

(3) Hub assembly

Hub sub assembly
Η Pressurize bolt.

20D7AXLE097

Θ Put a bearing cup on the upper and lower of hub.

20D7AXLE098

3-69
Ι Pressurize bearing cup.

20D7AXLE099

Κ Spread grease on the bearing of flange.

20D7AXLE100

Λ Fix bearing into hub.

20D7AXLE101

Μ Spread grease in the oil seal.

20D7AXLE102

Ν Spread sealant on the outside of oil.

20D7AXLE103

3-70
Ξ Pressurize oil seal.

20D7AXLE104

Ο Spread grease on the bearing of axle.

20D7AXLE105

Π Fix bearing into hub.

20D7AXLE106

Ρ Spread grease on hub.

20D7AXLE107

Hub assembly
Η Spread grease on the flange shaft.

20D7AXLE108

3-71
Θ Fix hub.

20D7AXLE109

Ι Fix plate.

20D7AXLE110

Κ Fix nut.

20D7AXLE111

Λ Fasten torque and loosen.

ÂTightening torque : 21~25 kgfÂm
(152~181 lbfÂft)

20D7AXLE112

Μ Adjust preload.
Â0.6~0.8 kgfÂm

20D7AXLE113

3-72
Ν Fit the position of plate, nut and hole.

20D7AXLE114

Ξ Spread loctite #277.

20D7AXLE115

Ο Confirm torque.
ÂTightening torque : 0.8~1.2 kgfÂm
(5.8~11 lbfÂft)

20D7AXLE116

Axle shaft assembly

Η Spread loctite #5127 on axle shaft.

20D7AXLE117

Θ Fix into hub.

20D7AXLE118

3-73
Ι Close to hub.

20D7AXLE119

Κ Spread loctite #277 on bolt.

ÂTightening torque : 6~7 kgfÂm
(43~51 lbfÂft)

20D7AXLE120

Λ Fasten torque.

20D7AXLE121

The rest part assembly

Η Assemble the air breather into LH.

20D7AXLE122

Θ Assemble the air breather into RH.

ö Spread loctite #577 on the air breather.
ÂTightening torque (LH, RH) : 1.5~2 kgfÂm
(11~14 lbfÂft)

20D7AXLE123

3-74
Ι Assemble hanger bolt.

20D7AXLE124

Κ Fix dipstick.

20D7AXLE125

Λ Assemble the magnetic plug.

ö Spread loctite #577 on plug.

Loctite #577
20D7PT36

3-75