12. Install the disc spring onto the reverse brake piston.
13. Starting with the reverse brake plate, install the reverse brake plates and discs one at a time. Install the reverse brake end plate and retaining ring.
14. Using a dial indicator, measure the clearance between the end plate and the upper disc of the reverse brake. Set the indicator to zero by lowering the end plate of the reverse brake and lifting it up to the retaining ring. The distance that the end plate of the reverse brake moves is the clearance between the end plate of the reverse brake and the upper disc. Standard: 0.45-0.75 mm.
Note: Measure at least three places and take the average value as the actual gap.
15. If the gap is different from the standard, remove the reverse brake end plate and measure its thickness.
16. Select a new reverse brake end plate and install it, then retest.
Note: If the thickest reverse brake end plate is installed but the clearance is not standard, replace the reverse brake discs and plates.
Reverse brake end plate
| Plate No | Catalogue No | Thickness |
| 1 | 22551-P4V-003 | 3.6 mm |
| 2 | 22552-P4V-003 | 3.8 mm |
| 3 | 22553-P4V-003 | 4.0 mm |
| 4 | 22554-P4V-003 | 4.2 mm |
| 5 | 22555-P4V-003 | 4.4 mm |
| 6 | 22556-P4V-003 | 4.6 mm |
| 7 | 22557-P4V-003 | 4.8 mm |
| 8 | 22558-P4V-003 | 5.0 mm |
17. After replacing the reverse brake end plate, make sure the clearance is within the normal range.
18. Remove the retaining ring, reverse brake end plate, discs and plates and disc spring.
19. Install the snap ring holder onto the drive pulley shaft.
20. To avoid damaging the O-rings, wrap the splined portion of the drive pulley shaft with electrical tape, then install new O-rings.
21. Install the forward clutch assembly onto the drive pulley shaft, then install the retaining ring.
22. Make sure the outer diameter of the snap ring is correct.
23. Install the sun gear/drive shaft assembly.
24. Install the thrust needle bearing and thrust washer onto the sun gear.
25. Install the carrier assembly onto the forward clutch.
26. Install the thrust washer, thrust needle bearing and thrust washer onto the planet carrier assembly.
27. Install the ring gear and 25x31mm thrust shim, then install the snap ring.
28. Make sure the outer diameter of the snap ring is correct.
29. Measure the gap between the 25x31mm thrust washer and the retaining ring. Standard: 0.05-0.11mm.
Note: Measure at least three places and take the average value as the actual gap.
30. If the gap differs from the standard, remove the 25x31 mm thrust shim and measure its thickness.
31. Select a new 25x31mm thrust washer and install it, then recheck.
Thrust washer, 25x31 mm
| № | Catalogue No | Thickness |
| A | 90451-P4V-000 | 1.05 mm |
| IN | 90452-P4V-000 | 1.12 mm |
| WITH | 90453-P4V-000 | 1.19 mm |
| D | 90454-P4V-000 | 1.26 mm |
| E | 90455-P4V-000 | 1.33 mm |
| F | 90456-P4V-000 | 1.40 mm |
| G | 90457-P4V-000 | 1.47 mm |
| N | 90458-P4V-000 | 1.54 mm |
| I | 90459-P4V-000 | 1.61 mm |
| J | 90460-P4V-000 | 1.68 mm |
| TO | 90461-P4V-000 | 1.75 mm |
| L | 90462-P4V-000 | 1.82 mm |
| M | 23980-P4V-000 | 1,085 mm |
| N | 23981-P4V-000 | 1,055 mm |
| ABOUT | 23982-P4V-000 | 1.225 mm |
| R | 23983-P4V-000 | 1.295 mm |
| Q | 23984-P4V-000 | 1.265 mm |
| R | 23985-P4V-000 | 1,435 mm |
| S | 23986-P4V-000 | 1.505 mm |
| T | 23987-P4V-000 | 1.575 mm |
| and | 23988-P4V-000 | 1,645 mm |
| V | 23989-P4V-000 | 1.715 mm |
| W | 23990-P4V-000 | 1,785 mm |
32. After replacing the 25x31mm thrust washer, ensure that the clearance is within tolerance and the outer diameter of the retaining ring is correct as specified in item 28.
33. Install the disc spring in the direction shown.
34. Starting with the reverse brake plate, install the reverse brake plates and discs one at a time. Install the selected reverse brake end plate, then install the retaining ring.
35. Make sure the clearance in the snap ring lock is correct.
36. Install tubes A and B, using new O-rings, onto the manual control valve body and intermediate crankcase.
37. Install the two alignment pins and a new gasket under the right cover onto the intermediate case, then install new O-rings onto the ATF feed pipes.
38. Install the right cover on the intermediate crankcase.
39. Install the parking brake pawl, spring and pawl shaft to the gearbox housing, then move the selector lever to a position other than P.
40. Install the secondary shaft with the selected 25x31 mm thrust washer (see above) as shown in the figure in the right column above.
41. To avoid damaging the O-rings, wrap the splined portion of the driven pulley shaft with electrical tape, then install new O-rings.
42. Assemble the secondary shaft drive gear assembly into the starting clutch assembly, then install them onto the driven pulley shaft.
43. Pull the handle of the special tool, then insert its tip into the hole on the driven pulley shaft and install the special tool on the starting clutch.
Caution! When installing the starting clutch and secondary shaft drive gear assembly using a special tool, do not allow dust or other foreign objects to enter the gearbox.
44. Press down on the handle of the special tool, then tighten the nut and securely seat the secondary shaft drive gear assembly onto the drive gear shaft.
45. Pull the handle of the special tool and remove it.
46. Install the crackers, then measure the gap between the crackers and the starting clutch guide. Standard: 0-0.13 mm.
Note: Measure at least three places and take the average as the actual gap.
47. If the gap differs from the standard, remove the crackers and measure their thickness.
48. Select new crackers and install them, then recheck.
Crackers, 25.5 mm
| № | Catalogue No | Thickness |
| A | 90429-P4V-000 | 2.9 mm |
| IN | 90430-P4V-000 | 3.0 mm |
| WITH | 90431-P4V-000 | 3.1 mm |
| D | 90432-P4V-000 | 3.2 mm |
49. After replacing the 25.5 mm crackers, make sure that the gap is within the normal range.
50. Install the cracker holder and retaining ring.
51.Make sure the outer diameter of the snap ring is correct.
52. Install the thrust washers, ATF pump drive sprocket hub and 22 x 28 mm thrust shim onto the drive shaft, then install the snap ring.
53. Make sure the outer diameter of the snap ring is correct.
54. Measure the gap between the 22x28 mm thrust washer and the retaining ring. Standard: 0.37-0.65 mm.
Note: Measure at least three places and take the average value as the actual gap.
55. If the gap differs from the standard, remove the 22x28 mm thrust washer and measure its thickness.
56. Select a new 22x28mm thrust washer and install it, then recheck.
Thrust washer, 22x28 mm
| № | Catalogue No | Thickness |
| WITH | 90573-P4V-000 | 1.15 mm |
| D | 90574 P4V-000 | 1.40 mm |
| E | 90575-P4V-000 | 1.65 mm |
| F | 90576-P4V-000 | 1.90 mm |
| G | 90577-P4V-000 | 2.15 mm |
| N | 90578-P4V-000 | 2.40 mm |
57. After replacing the 22 x 28 mm thrust washer, check that the clearance is within specification and that the outer diameter of the retaining ring is correct.
58. Install the Pitot flange using its cutout as shown in the figure so as not to cover the Pitot tubes.
59. Install the ATF pump drive sprocket and place the ATF pump drive chain on the ATF pump drive and driven sprockets, then install and tighten the bolts (three bolts).
60. Install the differential assembly.
61. Install the ATF feed pipe using new O-rings.
62. Install three reference pins and a new flywheel gasket onto the gearbox housing.
63. Install the flywheel housing onto the gearbox housing.
64. Install the flywheel housing mounting bolts and tighten them:
- 18 bolts and connector bracket on the flywheel housing side.
- 3 bolts on the gearbox housing side.
65. Install the ATF feed tube holder assembly.
1. 6x1.0 mm, 12 Nm (1.2 kgf/m)
2. FLYWHEEL CASE
3. FLYWHEEL CASE FASTENING BOLT, 8x1.25 mm, 29 Nm (3.0 kgf/m), 18 bolts
4. REFERENCE PIN, 12x20 mm
5. ATF SUPPLY PIPE ASSEMBLY
6. 6x1.0 mm, 12 Nm (1.2 kgf/m)
7. O-RING. Replace
8. REFERENCE PIN, 10x16 mm
9. GEARBOX CASE
10. ATF SUPPLY PIPE GUIDE
11. ATF SUPPLY PIPE ASSEMBLY
12. FLYWHEEL CASE FASTENING BOLT. 8x1.25 mm, 29 Nm (3.0 kgf/m), 3 bolts
13. REFERENCE PIN, 10x16 mm
14. DIFFERENTIAL ASSEMBLY
15. FLYWHEEL HOUSING GASKET. Replace.
16. CONNECTOR BRACKET
17. O-RING. Replace
18. ATFBCBOPE FLUID SUPPLY TUBE HOLDER
66. Reconnect the solenoid harness connector using a new O-ring and install the lower valve body assembly using the three dowel pins and eight bolts.
67. Install the ATF coarse filter with a new O-ring and two bolts.
68. If necessary, assemble the ATF fluid pan, ATF filter and ATF cooler feed pipes (see above).
69. Install the ATF pan using the two alignment pins, a new gasket and 14 bolts.
70. Secure the ATF cooler feed pipe to the bracket with the 8mm bolt.
1. 6x1.0 mm, 12 Nm (1.2 kgf/m)
2. O-RING. Replace
3. LOWER VALVE BODY ASSEMBLY
4. REFERENCE PINS
5. GEARBOX CASE
6. O-RING. Replace
7. SOLENOID HARNESS CONNECTOR
8. 6x1.0 mm, 12 Nm (1.2 kgf/m)
9. 6x1.0 mm, 12 Nm (1.2 kgf/m), 8 bolts
10. REFERENCE PIN
11. ATF COOLER FEED PIPE BRACKET BOLT, 8x1.25mm, 26Nm (2.7kgf/m)
12. ATF FLUID PAN
13. 6x1.0 mm, 12 Nm (1.2 kgf/m), 14 bolts
14. REFERENCE PIN
15. ATF PAN GASKET Replace
16. ROUGH FILTER for ATF fluid
71. Place the breather cap on the breather tube so that the arrow points towards the flywheel housing.
Note: Item 72 and 73 apply to the 4WD gearbox.
72. Clean the areas where the transfer case assembly and transmission meet with solvent or carburetor cleaner and dry with compressed air. Then apply transmission fluid to the contact areas.
73. Install the transfer case assembly onto the gearbox, installing new O-rings. Do not allow dust or other foreign objects to enter the gearbox.
1. DRIVE DISC
2. Washer. Install in this direction
3. FLYWHEEL, Check the ring gear teeth for excessive wear
4. 12x1.0 mm, 74 Nm (7.5 kgf/m). Tighten crosswise