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 90Á.

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