Almera Tino V10 (2003 year). Manual — part 31

REPAIR FOR COMPONENT PARTS

AT-481

[ALL]

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3.

Install thrust washer on rear internal gear.

●

Apply petroleum jelly to thrust washer.

●

Align hooks of thrust washer with holes of rear internal
gear.

4.

Install end bearing on rear internal gear.

●

Apply petroleum jelly to end bearing.

5.

Install forward clutch hub on rear internal gear.

●

Check operation of forward one-way clutch.
Hold rear internal gear and turn forward clutch hub.
Check forward clutch hub for correct locking and unlock-
ing directions.

●

If not as shown in illustration, check installation direction
of forward one-way clutch.

6.

Install thrust washer and overrun clutch hub.

●

Apply petroleum jelly to thrust washer.

●

Align pawls of thrust washer with holes of overrun clutch
hub.

7.

Install overrun clutch hub on rear internal gear.

●

Align projections of rear internal gear with holes of over-
run clutch hub.

SAT160F

MCIB9021E

SAT713H

SAT263D

SAT264D

AT-482

[ALL]

REPAIR FOR COMPONENT PARTS

8.

Install snap ring to groove of rear internal gear.

Output Shaft, Idler Gear, Reduction Pinion Gear and Bearing Retainer

ECS009CR

COMPONENTS

DISASSEMBLY

1.

Remove seal rings from output shaft and bearing retainer.

SAT248D

SAT487JA

SAT644D

REPAIR FOR COMPONENT PARTS

AT-483

[ALL]

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2.

Remove output shaft bearing with screwdrivers.

●

Always replace bearing with a new one when removed.

●

Do not damage output shaft.

3.

Remove snap ring from bearing retainer.

4.

Remove needle bearing from bearing retainer.

5.

Remove idler gear bearing inner race from idler gear.

6.

Remove idler gear bearing outer race from transmission case.

SAT645D

SAT646D

AAT539

SAT648D

AAT495

AT-484

[ALL]

REPAIR FOR COMPONENT PARTS

7.

Press out reduction pinion gear bearing from reduction pinion
gear.

8.

Remove reduction pinion gear bearing outer race from transmis-
sion case.

INSPECTION
Output Shaft, Idler Gear and Reduction Pinion Gear

●

Check shafts for cracks, wear or bending.

●

Check gears for wear, chips and cracks.

Bearing

●

Make sure bearings roll freely and are free from noise, cracks,
pitting or wear.

●

When replacing taper roller bearing, replace outer and inner
race as a set.

Seal Ring Clearance

●

Install new seal rings to output shaft.

●

Measure clearance between seal ring and ring groove of output
shaft.

●

If not within allowable limit, replace output shaft.

●

Install new seal rings to bearing retainer.

●

Measure clearance between seal ring and ring groove of bearing retainer.

AAT538

SAT651D

SPD715

Standard clearance:

0.10 - 0.25 mm (0.0039 - 0.0098 in)

Allowable limit:

0.25 mm (0.0098 in)

Standard clearance:

0.10 - 0.25 mm (0.0039 - 0.0098 in)

SAT652D

REPAIR FOR COMPONENT PARTS

AT-485

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●

If not within allowable limit, replace bearing retainer.

ASSEMBLY

1.

Press reduction pinion gear bearing on reduction pinion gear.

2.

Install reduction pinion gear bearing outer race on transmission
case.

3.

Press idler gear bearing inner race on idler gear.

4.

Install idler gear bearing outer race on transmission case.

Allowable limit:

0.25 mm (0.0098 in)

AAT688

SAT654D

AAT689

SAT901D

AT-486

[ALL]

REPAIR FOR COMPONENT PARTS

5.

Press output shaft bearing on output shaft.

6.

Press needle bearing on bearing retainer.

7.

Install snap ring to bearing retainer.

8.

After packing ring grooves with petroleum jelly, carefully install
new seal rings on output shaft and bearing retainer.

●

Roll paper around seal rings to prevent seal rings from
spreading.

SAT939D

SAT658D

SAT659D

SAT660D

SAT661D

REPAIR FOR COMPONENT PARTS

AT-487

[ALL]

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Band Servo Piston Assembly

ECS009CS

COMPONENT

DISASSEMBLY

1.

Remove band servo piston snap ring.

2.

Apply compressed air to oil hole in transmission case to remove
OD servo piston retainer and band servo piston assembly.

●

Hold band servo piston assembly with a rag or nylon
waste.

3.

Apply compressed air to oil hole in OD servo piston retainer to
remove O/D servo piston from retainer.

●

Hold OD band servo piston while applying compressed
air.

SAT098K

SAT288D

SAT289D

SAT290DB

AT-488

[ALL]

REPAIR FOR COMPONENT PARTS

4.

Remove D-ring from OD servo piston.

5.

Remove O-rings from OD servo piston retainer.

6.

Remove band servo piston assembly from servo piston retainer
by pushing it forward.

7.

Place piston stem end on a wooden block. While pushing servo
piston spring retainer down, remove E-ring.

8.

Remove OD servo return spring, band servo thrust washer and
band servo piston stem from band servo piston.

SAT593GB

SAT292DA

SAT293D

SAT294D

SAT295DA

REPAIR FOR COMPONENT PARTS

AT-489

[ALL]

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9.

Remove O-rings from servo piston retainer.

10. Remove D-rings from band servo piston.

INSPECTION
Pistons, Retainers and Piston Stem

●

Check frictional surfaces for abnormal wear or damage.

Return Springs

●

Check for deformation or damage.

●

Measure free length and outer diameter.

SAT296DA

SAT594GA

SAT298DA

Inspection standard:

Refer to

AT-519, "SERVICE DATA AND SPECIFICA-

TIONS (SDS)"

SAT138D

AT-490

[ALL]

REPAIR FOR COMPONENT PARTS

ASSEMBLY

1.

Install D-rings to servo piston retainer.

●

Apply ATF to D-rings.

●

Pay attention to position of each D-ring.

2.

Install band servo piston stem, band servo thrust washer, OD
servo return spring and spring retainer to band servo piston.

3.

Place piston stem end on a wooden block. While pushing servo
piston spring retainer down, install E-ring.

4.

Install O-rings to servo piston retainer.

●

Apply ATF to O-rings.

●

Pay attention to position of each O-ring.

SAT595GA

SAT295DA

SAT301D

SAT296DA

REPAIR FOR COMPONENT PARTS

AT-491

[ALL]

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5.

Install band servo piston assembly to servo piston retainer by
pushing it inward.

6.

Install D-ring to OD servo piston.

●

Apply ATF to D-ring.

7.

Install O-rings to OD servo piston retainer.

●

Apply ATF to O-rings.

●

Pay attention to position of each O-ring.

8.

Install OD servo piston to OD servo piston retainer.

9.

Install band servo piston assembly and second servo return
spring to transmission case.

●

Apply ATF to O-ring of band servo piston and transmis-
sion case.

SAT303D

SAT596GB

SAT292DA

SAT306DA

SAT865H

AT-492

[ALL]

REPAIR FOR COMPONENT PARTS

10. Install OD servo piston assembly to transmission case.

●

Apply ATF to O-ring of band servo piston and transmis-
sion case.

11. Install band servo piston snap ring to transmission case.

Final Drive

ECS009CT

COMPONENTS

DISASSEMBLY

1.

Remove final gear.

AAT692

SAT288D

MCIB9024E

SMT505B

REPAIR FOR COMPONENT PARTS

AT-493

[ALL]

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2.

Press out differential side bearings.

●

Be careful not to mix up the right and left bearings.

3.

Remove speedometer drive gear.

4.

Drive out pinion mate shaft lock pin.

5.

Draw out pinion mate shaft lock pin.

6.

Remove pinion mate gears and from differential case.

SAT312D

SAT313D

SAT904DA

SAT316D

AT-494

[ALL]

REPAIR FOR COMPONENT PARTS

INSPECTION
Gear, Washer, Shaft and Case

●

Check mating surfaces of differential case, side gears and pin-
ion mate gears.

●

Check washers for wear.

Bearings

●

Make sure bearings roll freely and are free from noise, cracks,
pitting or wear.

●

When replacing taper roller bearing, replace outer and inner
race as a set.

ASSEMBLY

1.

Install side gear and thrust washers in differential case.

2.

Install pinion mate gears and thrust washers in differential case
while rotating them.

●

When inserting, be careful not to damage pinion mate
gear washers.

●

Apply ATF to any parts.

3.

Measure clearance between side gear and differential case with
washers using the following procedure:

a.

Set Tool and dial indicator on side gear.

MCIB9022E

SPD715

SAT318D

SAT902D

REPAIR FOR COMPONENT PARTS

AT-495

[ALL]

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b.

Move side gear up and down to measure dial indicator deflec-
tion. Always measure indicator deflection on both side gears.

c.

If not within specification, adjust clearance by changing thickness of differential side gear thrust washers.

4.

Install lock pin.

●

Make sure that lock pin is flush with case.

5.

Install speedometer drive gear on differential case.

●

Align the projection of speedometer drive gear with the
groove of differential case.

6.

Install final gear and tighten fixing bolts in a numerical order.

Clearance between side gear and differential case
with washer:

0.1 - 0.2 mm (0.004 - 0.008 in)

SMT616

Differential side gear thrust washers:

Refer to

AT-519, "SERVICE DATA AND SPECIFICA-

TIONS (SDS)"

.

SAT904D

SAT313D

SAT326D

AT-496

[ALL]

REPAIR FOR COMPONENT PARTS

7.

Press on differential side bearings.

SMT700B