GROUP 3 DISASSEMBLY AND ASSEMBLY

1. DISASSEMBLY OF TRANSMISSION
1) DISASSEMBLING OF TRANSMISSION ASSY
(1) Drain the transmission oil.
Remove the drain plug at T/C housing.
(2) Lay the wood plate (or plastic plate) on the
workshop's table (bottom).
And put the T/M assy on the wood plate (or plastic
plate) : For an (dis)assembly at the time of damage
prevent.
15L7ATM001
To avoid serious personal injury and possible
damage to components, be very careful when
using lifting devices during removal and
disassembly procedures.

(3) Removal torque converter part.

Η Remove the torque converter sub assy.
T/C sub assy

15L7ATM002

Θ Remove the hexagon bolt , washer, flexible plate.

15L7ATM003

(4) Remove the PTO shaft.

15L7ATM004

3-100
(5) Remove the socket gear.
Next remove the snap-ring at socket gear.

15L7ATM005

(6) Removal the oil pump sub assy.

Η Remove the hexagon bolt (M8Ý1.25PÝ38L), and
then remove the copper washer.

15L7ATM006

Θ Remove the plug. (PT 1/8)

15L7ATM007

Ι Remove the pump sub assy + gasket using the

plug hole for pulling out from the T/C housing.
(use M8Ý1.25PÝ38L hexagon bolt)

15L7ATM008

Κ Remove the O-ring at pump sub assy.

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(7) Removal the control valve sub assy.
Η Remove the hexagon bolt (M8Ý1.25PÝ60L).

15L7ATM010

Θ Remove the part slowly with hit the end side softly.
ö Using a plastic hammer .
Do not hit steel parts with a steel hammer.
Pieces of a part can break off and cause serious
personal injury.

15L7ATM011

Ι Remove the control valve assy, and then remove

the gasket.

15L7ATM012

(8) Remove the oil filter, and then remove the filter
adapter.

15L7ATM013

(9) Remove the (T/C in relief, cooler relief) plug, and

then remove the spring, steel ball.
Next remove the O-ring at relief plug.

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(10) Remove the cooler (in/out) plug.(PT 3/8)

15L7ATM015

(11) Remove the air breather.

15L7ATM016

(12) Remove the hexagon bolt, and then remove the T/C
cover.

15L7ATM017

(13) Remove the oil level gauge.

15L7ATM018

(14) Remove the socket bolt, and then remove the

clamp.

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3-103
(15) Remove the socket bolt, and then remove the pipe.
Next remove the O-ring at the pipe.

15L7ATM020

(16) Remove the temperature sensor.

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(17) Lay the T/M assy without damage to the T/C

housing.(engine mounting surface)

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(18) Remove the plug, and then remove the spring, oil
strainer.
Next remove the O-ring at the plug.

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(19) Remove the plug.(PT 1/8)

15L7ATM024

(20) Remove the socket bolt (T/M case + T/C housing

fastening bolt) 4 socket bolt exclusions.

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15L7ATM026

(21) To turn over T/M assy without damage to the T/M

case.(main pump mounting surface)
Next remove the 4 socket bolt.

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3-105
(22) Remove the part slowly with hit the end side softly.
ö Using a plastic hammer.

15L7ATM028

(23) Remove the T/C housing.

15L7ATM029

(24) Gear assemblies arrangements.

15L7ATM030

(25) Remove the O-ring.

15L7ATM031

(26) Remove the output gear assy.

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(27) Remove the idle gear assy.

15L7ATM033

(28) Remove the clutch gear assy.

ö Store each gear assembly in separate box.

15L7ATM034

(29) Remove the oil seal.

15L7ATM035

3-107
2) DISASSEMBLING OF GEAR ASSEMBLIES
(1) Disassembling clutch gear assy.

15L7ATM036

Η Remove the seal ring.

15L7ATM037

Θ Pull out the bearing(#6207) and spacer from the

shaft.

15L7ATM038

Ι Pull out the forward clutch sub assy.

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Κ Pull out the bearing(#6911) from the shaft.

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Λ Pull out the reverse clutch sub assy.

15L7ATM041

Μ Forward clutch sub assy.

15L7ATM042

Ν Remove the forward clutch gear sub, and then

remove the spacer.

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Ξ Remove the snap ring, and then remove the

bearing.

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Ο Remove the snap ring, and then remove the back
plate, friction disk, and steel plate.

15L7ATM045

Π Remove the wire ring, and then remove the back

plate and spring.
When you remove the wire-ring, it might be shot
out by impact of spring. Certainly fixing the
spring, will have to remove.
Ρ Pull out the clutch piston, and then remove the seal
ring.
Next remove the quad ring at the clutch piston.

15L7ATM046

΢ Reverse clutch sub assy.

15L7ATM047

Σ Remove the reverse clutch gear sub.

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Τ Remove the snap ring, and then remove the
bearing.

15L7ATM049

Υ Remove the snap ring, and then remove the back

plate, friction disk, and steel plate.

15L7ATM050

 Remove the wire ring, and then remove the back

plate and spring.
When you remove the wire-ring, it might be shot
out by impact of spring.
Certainly fixing the spring, will have to remove.
 Pull out the clutch piston, and then remove the seal
ring.
Next remove the quad ring at the clutch piston.

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(2) Disassembling of Idle gear assy.

15L7ATM052

Η Pull out the bearing, and then remove the idle gear
upper(lower).

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(3) Disassembling of output gear assy.

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Η Remove the seal ring, oil seal and sealing cap.

15L7ATM055

Θ Pull out the bearing.

15L7ATM056

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2. ASSEMBLY OF TRANSMISSION
1) ASSEMBLING OF GEAR ASSEMBLIES
ö Assemble the part with reverse the aforementioned disassemble procedure.

 Assembling of clutch gear assembly.

(1) Forward clutch drum sub assembly.
Η In drum internal groove tefron seal assembly.
ö Spread grease on seal ring.

15L7ATM057

Θ In piston groove quad ring assembly.

ö Spread grease on seal ring.

15L7ATM058

Ι Assemble piston at the drum.

15L7ATM059

Κ Assemble return spring, plate back and wire ring at

the drum sub.
ö When you assemble the wire ring, it might be shot
out by impact of spring.
Certainly fixing the spring, will have to assemble.

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3-114
Λ First insert steel plate, and then insert friction disk
alternately.
Next insert the back plate, and then assemble the
snap ring.

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Μ Assemble the bearing, and then assemble the

snap ring alternately.

15L7ATM062

Ν Arrange serration of the friction disk, and then

assemble the spacer, clutch gear sub.

15L7ATM063

Ξ Forward clutch drum sub assembly.

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3-115
(2) Reverse clutch drum sub assembly.
Η Do work as the same way like forward clutch drum
sub assembly procedure 1) Η ~ Λ.
Θ Assemble the bearing, and then assemble the
snap ring alternately.

15L7ATM065

Ι Arrange serration of the friction disk, and then

assemble the clutch gear sub.

15L7ATM066

Κ Reverse clutch drum sub assembly.

15L7ATM067

(3) Clutch gear assembly

Η Assemble the reverse clutch drum sub assy at the
shaft sub assy.

15L7ATM068

Θ Assemble the bearing.

- Used method of heating bearing.
ö All bearings should never be heated above 120ÁC

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3-116
Ι Assemble the forward clutch drum sub assy at the
shaft sub assy.

15L7ATM070

Κ Assemble the spacer and bearing.

- Used method of heating bearing.

15L7ATM071

Λ Assemble the seal ring.

ö Spread grease on seal ring

15L7ATM072

Μ Clutch gear assy.

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3-117
Assembling of output gear assembly.
Η Assemble the bearing.
- Used method of heating bearing
ö All bearings should never be heated above 120ÁC

15L7ATM074

Θ Assemble the oil seal, seal ring and sealing cap.

ö Spread loctite #609 on the out wheel of oil seal,
spread grease on inside wheel of oil seal.
ö Spread grease on seal ring.
ö Spread loctite #592 on the out wheel of sealing
cap.

15L7ATM075

Ι Output gear assy.

15L7ATM076

3-118
 Assembling of idle gear assembly.
Η Press the idle gear upper and idle gear lower at the
idle gear shaft, and then assemble the bearing.
- Used method of heating bearing
ö All bearings should never be heated above 120ÁC

15L7ATM077

Θ Idle gear assy.

15L7ATM078

3-119
2) ASSEMBLING OF TRANSMISSION ASSY
(1) Press the oil seal.
ö Spread loctite #592 on the out wheel of oil seal,
spread grease on inside wheel of oil seal.

15L7ATM079

(2) Assemble the clutch gear assy.

ö When you insert the shaft after install the seal ring in
the shaft, please insert the shaft with turning it into
the shaft side and hole side of shaft for prevent the
damage of shaft.

15L7ATM080

(3) Assemble the idle gear assy.

15L7ATM081

(4) Assemble the output gear assy.

15L7ATM082

(5) Assemble the O-rings.

ö Spread grease on O-ring.

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3-120
(6) Press the lock-pins.
ö After the assembling, please check whether you can
turn the input(output) gear lightly by your hand.

15L7ATM084

(7) Spread loctite #5127 on T/C housing space.

15L7ATM085

(8) Assemble the T/C housing.

15L7ATM086

(9) Assemble the part slowly with hit the end side softly.
ö Using a plastic hammer.

15L7ATM087

(10) Assemble the socket bolts.

(T/M case+ T/C housing softly fastening)

15L7ATM088

3-121
(11) Turn over T/M assy without damage to the T/C
housing.(engine mounting surface)
Next assemble the socket bolts.
ÂSocket bolt (M10Ý1.5pÝ40mm) Ý16EA
ÂTightening torque : 5.5~6.5 kgfÂm(40~47 lbfÂft)
ö Spread loctite #277 on socket bolt.

15L7ATM089

(12) Assemble the socket bolts.

ÂSocket bolt (M10Ý1.5pÝ25mm) Ý2EA
ÂTightening torque : 5.5~6.5 kgfÂm(40~47 lbfÂft)
ö Spread loctite #277 on socket bolt.

15L7ATM090

(13) Assemble the socket bolts.

ÂSocket bolt (M10Ý1.5pÝ30mm) Ý2EA
ÂTightening torque : 5.5~6.5 kgfÂm(40~47 lbfÂft)
ö Spread loctite #277 on socket bolt.

15L7ATM091

(14) Assemble the plugs(PT 1/8) Ý8EA

ÂTightening torque : 1.0~1.5 kgfÂm(7.0~11 lbfÂft)
ö Spread loctite #577 on plug.

15L7ATM092

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(15) Assemble the O-ring at the plug.
Insert the oil strainer, spring ,and then assemble O-
ring+plug assy.
ÂPlug tightening torque : 8~10 kgfÂm(58~72 lbfÂft)
ö Spread grease on O-ring.

15L7ATM093

(16) Assemble the temperature sensor.

ÂTightening torque : 3.0~4.0 kgfÂm(22~29 lbfÂft)
ö Spread loctite #577 on temperature sensor.

15L7ATM094

(17) Assemble the O-ring at the pipe, and then assemble

the pipe+O-ring assy.
Next assemble the socket bolts.
ÂSocket bolt (M8Ý1.5pÝ15mm) Ý2EA
ÂTightening torque : 3.0~3.3 kgfÂm(22~24 lbfÂft)
ö Spread grease on O-ring.
ö Spread loctite #277 on socket bolt.
15L7ATM095

(18) Assemble the clamp at the pipe,

and then assemble the socket bolt.
ÂSocket bolt (M10Ý1.5pÝ30mm)
ÂTightening torque : 5.5~6.5 kgfÂm(40~47 lbfÂft)
ö Spread loctite #277 on socket bolt.

15L7ATM096

(19) Assemble the oil level gauge at the pipe.

15L7ATM097

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(20) Assemble the T/C cover and hexagon bolts.
ÂHexagon bolt (M8Ý1.25pÝ16mm) Ý2EA
ÂTightening torque : 2.0~3.0 kgfÂm(14.5~21.7 lbfÂft)
ö Spread loctite #277 on socket bolt.

15L7ATM098

(21) Assemble the air breather.

ÂTightening torque : 1.0~1.5 kgfÂm(7.0~11 lbfÂft)
ö Spread loctite #577 on air breather.

15L7ATM099

(22) Assemble the O-ring at the plug, and then insert

steel ball, spring.
Next assemble O-ring+plug assy.
- Plug(3/4-16 UNF)Ý2EA
ÂTightening torque : 3.5~4.5 kgfÂm(25~33 lbfÂft)
ö Spread loctite #577 on plug.
ö Spread grease on O-ring.
15L7ATM100

(23) Assemble the adapter filter, and then assemble the

oil filter.
- Adapter filter
ÂTightening torque : 3.5~4.5 kgfÂm(25~32 lbfÂft)
ö Spread loctite #277 on adapter filter.
- Oil filter
ÂTightening torque : 0.8~1.2 kgfÂm(5.8~8.7 lbfÂft)
15L7ATM101

(24) Install the gasket, and then install the control valve
assy.
ö Spread grease on gasket.

15L7ATM102

3-124
(25) Assemble the hex bolt.
ÂHexagon bolt (M8Ý1.25pÝ60mm) Ý10EA
ÂTightening torque : 3.0~3.3 kgfÂm(22~24 lbfÂft)

15L7ATM103

(26) Assemble the o-ring at the charging pump assy.

ö Spread grease on O-ring.

15L7ATM104

(27) Install the gasket at the T/C housing, and then install
the charging pump assy.
Next assemble the hexagon bolt and bronze
washer.
ö Spread grease on gasket.
ÂHexagon bolt (M8Ý1.25pÝ38L) Ý4EA
ÂTightening torque : 2.8~3.8 kgfÂm(20.2~27.5 lbfÂft)
15L7ATM105
ö Spread loctite #242 on hexagon bolt.

(28) Assemble the snap ring at the socket gear, and then
insert the socket gear sub assy at the cylinder gear
assy.

15L7ATM106

(29) Insert the PTO shaft.

15L7ATM107

3-125
(30) Install the flexible plate at the torque converter, and
then install the hexagon bolt and washer.
ÂHexagon bolt (3/8-24UNF-2B) Ý6EA
ÂTightening torque : 3.0~3.5 kgfÂm(21.6~25.3 lbfÂft)
ö Spread loctite #277 on hexagon bolt

15L7ATM108

(31) Insert the T/C sub assy at the T/M sub assy.

15L7ATM109

(32) Transmission assy.

15L7ATM110

ö Speed sensor plug(option)

In T/M CASE internal groove O-ring assembly, and
then insert the adapter at the T/M case.
Next assemble the O-ring+ plug at the adapter.
ÂSocket bolt (M6Ý1.0pÝ20mm)
ÂTightening torque : 0.5~0.8 kgfÂm (3.7~6 lbfÂft)
ö Spread loctite #242 on socket bolt.
15L7ATM111
ö Spread grease on O-ring.

15L7ATM112

3-126
3. DISASSEMBLY OF DRIVE AXLE
1) DISASSEMBLY
(1) Disassembling of drive axle assy.

15L7ADA001

(2) Remove bolts of hub sub assembly.

To avoid serious personal injury and possible
damage to components, be very careful when
using lifting devices during removal and
disassembly procedures.
- Inspect to make sure that neither lifting strap is
damaged.
15L7ADA002
- Do not subject lifting straps to any shock or drop
loading.

(3) After support hub sub assembly by lifting device,

make hub sub assembly separate at the same
intervals by tightening two jack screw.
Use care when you remove the hub assembly to
prevent the hub assembly from falling off of the
lifting device. Do not drop the hub assembly.
Damage to the hub assembly and serious
personal injury can result. 15L7ADA003

(4) Disassemble in order of separate plate Ą friction

plate Ą cone spring.

15L7ADA004

3-127
(5) Remove pins.

15L7ADA005

(6) Disassemble in order of special bolt Ą return spring.

15L7ADA006

(7) Detach brake piston.

15L7ADA007

(8) After remove retaining ring, pull out left axle shaft.
(Do work as the same way like right axle shaft)
Use a brass, leather or rubber mallet for
assembly and disassembly procedures.
Do not hit steel parts with a steel hammer.
Pieces of a part can break off and cause serious
personal injury.
15L7ADA008

(9) Disassembling of hub sub assy.

15L7ADA009

3-128
(10) Remove all snap rings.

15L7ADA010

(11) Remove all each parts in order of thrust washer Ą

planet gear Ą needle bearing Ą thrust washer.

15L7ADA011

(12) Loose lock nut by using jig.

15L7ADA012

(13) Extract planet carrier.

15L7ADA013

(14) Extract carrier housing with bearing.

15L7ADA014

3-129
(15) Remove bolts fixing flange hub and wheel shaft.

15L7ADA015

(16) Remove bolts fixing carrier assy.

15L7ADA016

(17) Extract the bracket.

15L7ADA017

(18) Extract carrier assembly.

15L7ADA018

(19) Fix carrier assembly to a jig.

15L7ADA019

3-130
(20) Remove carrier cap bolt.

15L7ADA020

(21) Extract the carrier cap (apply marking a match).

15L7ADA021

(22) Remove adjusting ring of both sides bearing cup.

15L7ADA022

(23) Extract differential assembly.

15L7ADA023

(24) After turn over carrier assy and fix it, remove nut.

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3-131
(25) Remove U-joint flange.

15L7ADA025

(26) Remove carrier case cover bolts.

15L7ADA026

(27) Extract carrier case cover assembly.

15L7ADA027

(28) Extract push pins and actuator.

15L7ADA028

(29) Remove O-ring and spline parking.

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3-132
(30) Remove parking friction plates and separate plates.

15L7ADA030

(31) Finish disassembling of carrier assembly.

15L7ADA031

3-133
2) ASSEMBLY
(1) Carrier sub assembly
Differential device assembly
Η Prepare parts for assembly of differential.

15L7ADA032

Θ Fix differential case RH and LH with bolt.

After paste loctite #277 on spiral of bolt.
Confirm torque : 350~380 kgfÂcm

15L7ADA033

Ι Assemble ring gear.

After paste loctite #277 on spiral of bolt.
Confirm torque : 710~760 kgfÂcm

15L7ADA034

Κ Assemble bearing.
Heating pressurize bearing cone.

15L7ADA035

3-134
 Adjusting shim and pinion shaft assembly
Η Fix carrier case to the jig.
ö Read the following information before installing new
gearset in the carrier. Always inspect the gearset
for correct marks to make sure the gears are a
matched set.

15L7ADA036

The locations of the gearset marks are shown in

right figure.
 Part number
a. Examples of gearset part numbers
- Conventional ring gear, XKCF-00513
- Conventional pinion shaft, XKCF-00514
ö Part No. : Refer to parts manual.
b. Location on pinion shaft : Shaft end 15L7ADA037

c. Location on ring gear : Front face or outer

diameter
 Tooth combination number
a. Example of a tooth combination number : 13-32
(An 13-32 gearset has an 13-tooth drive pinion
and a 32-tooth ring gear)
b. Location on pinion shaft : Shaft end
c. Location on ring gear : Front face or outer
diameter
 Pinion cone variation number
(The pinion cone variation number is not used
when checking for a matched gearset. The number
is used when you adjust the depth of the pinion in
the carrier.)
a. Examples - Pinion cone variation numbers
Â+2
Â+0.01mm
Â-1
Â-0.02mm
b. Location on gearset
End of pinion shaft head or outer diameter of ring
gear

3-135
Θ Decide thickness of shim by gauge and measuring
apparatus (Standard gap between bearing and
carrier case step : A)
(Mounting distance(MD) of pinion shaft : B)
ö Thickness of shim
ÂX = A - B + Carrier case bearing step depth
ex1) A= 0.35, B= -0.1, Bearing step depth= +0.1
ÂX = 0.35 + 0.1 + 0.1 = 0.55mm 15L7ADA038

ex2) A= 0.35, B= +0.1, Bearing step depth= -0.1

ÂX = 0.35 - 0.1 - 0.1 = 0.15mm

Ι Assemble shim.
ö Sort of shim : 0.1 , 0.15 , 0.25 , 0.5 (mm)

15L7ADA039

Κ Pressurize bearing cup.

15L7ADA040

Λ Put with heating bearing cone on pinion shaft.

15L7ADA041

Μ Put into pinion shaft.

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3-136
Ν Set a ball.

15L7ADA043

Ξ Equip jig for fixing.

15L7ADA044

Ο Fasten the ball.

15L7ADA045

Π Revolve carrier case 180Á.

15L7ADA046

Ρ Put into spacer.

15L7ADA047

3-137
΢ Decide thickness of shim by gauge and measuring
apparatus (thickness : B)
ö Thickness of shim
ÂX = B - End play (0.03~0.06)
ex 1) B = 0.45,
ÂX = 0.45 - (0.03~0.06) = 0.42~0.39mm

15L7ADA048

Σ Remove pinion shaft.

15L7ADA049

Τ Pressurize bearing cup.

15L7ADA050

Υ Assemble again pinion shaft and the jig.

Assemble after paste grease on bearing cone
roller.

15L7ADA051

 Assemble shim.
ö Sort of shim : 0.1 , 0.15 , 0.2 (mm)

15L7ADA052

3-138
 Assemble bearing cone.
Assemble after paste grease on bearing cone
roller.

15L7ADA053

Assemble of parking sub assembly

Η Assemble pin into carrier case.

15L7ADA054

Θ Assemble in order of separate plate Ą cone spring

Ą friction plate.
But assemble separate plate lastly.
ÂSeparate plates : 4EA
ÂFriction plates : 3EA

15L7ADA055

Ι Assembles actuator in assembly direction.

15L7ADA056

Κ Assemble spline parking maching with friction plate

spline.

15L7ADA057

3-139
Λ Assemble push pin into actuator.

15L7ADA058

Μ Assemble O-ring on groove of pinion shaft.

Assemble after paste grease on O-ring grease.

15L7ADA059

Ν Assemble pin into the carrier case.

15L7ADA060

Assemble of carrier case cover assemble

Η Assemble oil seal into carrier case cover.
Paste #592 on outside of oil seal and grease on
inside of oil seal.

15L7ADA061

Θ Assemble eccentric shaft.

Put into longer shaft first.

15L7ADA062

3-140
Ι Assemble cover by first putting small O-ring on
eccentric shaft, and then put big O-ring on collor.

15L7ADA063

Κ Assemble set screw.

Assemble paste loctite #277.
Confirm torque : 200~250 kgfÂcm

15L7ADA064

Λ After complete assembling of axle when pull

parking lever. The stroke have to be keeped
11~21mm.

15L7ADA065

15L7ADA064-1

Μ Fix lever with snap ring.

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3-141
Ν Assemble cap.
Assemble after paste loctite #609.

15L7ADA067

Ξ Assemble carrier cover assy.

Assemble after paste loctite #277.
Confirm torque : 304~405 kgfÂcm
Paste loctite #5127 on assembling side of carrier
case cover and carrier case.

15L7ADA068

ö Applying liquid gasket material.

ö Take care when you use liquid gasket materials to
avoid serious personal injury.
Follow the manufacturer's instructions to prevent
irritation to the eyes and skin.
 Remove all oil gasket material from both surfaces.
 Clean the surfaces where liquid gasket material
15L7ADA069
will be applied. Remove all oil, grease, dirt and
moisture without damaging the mating surfaces.
 Dry both surfaces.

ö The amount of liquid gasket material applied must not exceed 3mm diameter bead.
Too much gasket material can block lubrication passages and result in damage to the
components.
 Apply 3mm maximum diameter continuous bead of the liquid gasket material around one
surface. Keep bead far away from bolt holes to prevent sealant from getting in between mating
threads during bolt installation.
This could significantly reduce the effectiveness of the thread locking compound.
Figure DA071.
 Assemble the components immediately to permit the liquid gasket material to compress evenly
between the parts.
Tighten fasteners to the specified torque.
 Wait 20 minutes before filling the assembly with lubricant.

3-142
Ο Assemble flange U-joint.

15L7ADA070

Π Fasten nut.
Assemble paste loctite #242.
Confirm torque : 2600~2950 kgfÂcm
ö Preload : 10~19 kgfÂcm

15L7ADA071

Ρ Calking. (2 EA)

15L7ADA072

΢ Assemble differential sub in carrier case.

15L7ADA073

Σ Fit carrier cap with steel ball.

Bolt : paste loctite #277
Confirm torque : 1170~1130 kgfÂcm

15L7ADA075

15L7ADA074

3-143
 Adjusting the gearset backlash
Η Assemble bearing adjust ring.

15L7ADA076

Θ Adjust bearing adjust ring.

15L7ADA077

Ι Measure backlash.

15L7ADA078

Κ Fasten bearing adjust ring.

15L7ADA079

Λ Measure again backlash.

ö Backlash of pinion and ring gear : 0.15~0.20mm
ö If backlash is wrong, carry out adjusting work.
Adjust the left/right of ring bearing adjust by one
and one clip.

15L7ADA080

3-144
ö Backlash is increased by moving the ring gear
away from the pinion shaft. Backlash is decreased
by moving the ring gear toward the pinion shaft.
Refer to figure DA076 and DA077.
Μ Loosen one bearing adjusting ring one notch, then
tighten the opposite ring the same amount.
Refer to figure DA076 and DA077.
15L7ADA081

15L7ADA082

Adjusting tooth contact pattern of the gearset

ö After assembling, adjust pattern of the gear and
pinion shaft figure.
If pattern is not adjusted, take a measure as
measuring backlash again and then reassemble.
ö Always check tooth contact pattern on the drive
side of the gear teeth. Figure DA084.
15L7ADA083

15L7ADA084

Η Apply marking compound to approximately 6 teeth

of the ring gear. Figure DA085.

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3-145
⯲ Rotate ring gear forward and backward so that the
6 marked teeth go past the drive pinion six time to
get a good contact pattern.

⯳ Compare the contact patterns to figure DA086,

DA087 and DA088.
⚰ In new gearsets, a good contact pattern is toward
the toe of the tooth, and centered between the top
and bottom of the tooth. Figure DA086.

15L7ADA086

15L7ADA087

15L7ADA088

⚰ In used gearsets, a good contact pattern fills

approximately the full length of the tooth.
The top of the pattern is near the top of the tooth.
The location should match the wear pattern on the
tooth. Figure DA089.

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⯴ If the contact patterns require adjustment along the
width of tooth (top/bottom), follow steps ⯗⯘
If the contact patterns require adjustment along the
length of tooth (toe/heel), follow steps ⯙⯚
⯗ High pattern : A high contact pattern indicates that
the pinion was installed too shallow into the
carrier. Figure DA087.
15L7ADA090
To correct, move the pinion toward the ring gear
by decreasing the shim pack between pinion
spigot and inner bearing cone.
Figure DA090.

⯘ Low pattern : A high contact pattern indicates that

the pinion was installed too deep into that the
pinion was installed too deep into the carrier.
Figure DA088.
To correct, move the pinion away from the ring
gear by increasing the shim pack between pinion
spigot and inner bearing cone.
Figure DA091.
15L7ADA091

⯙ Heel pattern : Decrease the gearset backlash

(within specified range) to move contact pattern
toward toe and away from heel. Refer to page 3-
144 "Adjusting the gearset backlash" figure
DA092.

15L7ADA092

⯚ Toe pattern : Increase the gearset backlash

(within specified range) to move contact pattern
toward heel and away from toe.
Refer to the pate 3-144 "Adjusting the gearset
backlash" figure DA093.

15L7ADA093

3-147
Λ Fix spring pin with ring bearing adjust.
And assemble them.

15L7ADA094

15L7ADA095

3-148
(2) Assemble of carrier assembly
Η Pressurize lock pin into axle housing.

15L7ADA096

Θ Paste sealant on axle housing.

(Loctite #5127)

15L7ADA097

Ι Assemble carrier assembly on axle housing.

15L7ADA098

Κ Fasten bolt.
Assemble bolt after spread loctite #277.
Confirm torque : 610~650 kgfÂcm

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3-149
(3) Traveling brake system assembly
Axle shaft assembly
Η Insert snap ring on the axle shaft.

15L7ADA100

Θ After put the ball bearing, fix it with snap ring.

15L7ADA101

Ι After put axle shaft into axle housing fix with snap
ring.

15L7ADA102

Piston assembly
Η Assemble ring (large and small) at brake piston.
ö When assembling quad ring, pay attent to
chopping.
ö Before assemble quad ring, coating oil.

15L7ADA103

Θ Assemble shim.

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3-150
ö When assembling the shim, you calculate the value
of the shim ad then assemble it.
 "L" : Piston assembling part axle housing stage
depth (standard : 56.9mm)
 "C":Carrier housing stage height (standard : 9mm)
 "F" : The total thickness of friction plate and
separate plate (standard : 20.5mm)
 "P":Piston thickness (standard : 27mm)
 "S":Brake stroke (basis stroke : 0.4mm)
 T":Shim

S = L-(C+F+P)
T = S-0.4 (basis stroke)
15L7ADA105
ex) if S = 0.5mm,
T = S-0.4 (basis stroke)
= 0.5-0.4 = 0.1mm
assemble for shim 0.1

Ι Assemble in order piston-brake Ą spring Ą

special bolt.
Bolt-special : Spread loctite
Confirm torque : 140~160 kgfÂcm

15L7ADA106

Κ Put pin into axle housing.

15L7ADA107

Λ Put in lock pin.

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3-151
Μ Assemble in order of separate plate Ą friction plate
Ą cone spring. But Assemble separate plate lastly.
(Separate plate : 4EA , friction plate : 3EA)

15L7ADA109

(4) Hub assembly

Hub sub assembly
Η Pressurize hub bolt.

15L7ADA110

Θ Pressurize oil seal with loctite #592.

Spread grease inside of oil seal.

15L7ADA111

Ι Put with heating bearing cone on wheel shaft.

Assemble after paste axle oil on roll of bearing
cone.

15L7ADA112

Κ Assemble O-ring coated grease at wheel shaft.

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3-152
Λ Assemble flange hub and wheel shaft.
ö Paste loctite #5127
Confirm torque : 600~700kgfÂcm
Bolt : Spread loctite #277

15L7ADA114

Μ Fix spacer.

15L7ADA115

Ν Assemble oil seal at carrier housing.

Oil seal with loctite #592.

15L7ADA116

Ξ Assemble bearing cup at carrier housing.

15L7ADA117

Ο Assemble bearing cup at upper side of carrier

housing.

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3-153
Π Put carrier housing on assembled flange hub and
wheel shaft. Before assembling, spread grease
inside of flange hub.
ÂGrease : Shell retinax 0434 - 60~80% spread

15L7ADA119

Ρ Adjust preload for fix shim.

ÂPreload : 40~50kgfÂcm

15L7ADA120

΢ Put into shim.

ö Sort of shim : 0.1 , 0.15 , 0.25 , 0.5 (mm)

15L7ADA121

Σ Pressurize bearing cone.

Before assembling, paste axle oil on roller of
bearing cone.

15L7ADA122

Τ Assemble planet carrier.

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3-154
Υ Fasten lock nut.
Confirm torque : 2800~3200kgfÂcm, calke after
assembling.
ÂPreload : 40~50kgfÂcm

15L7ADA124

 Assemble in order of washer Ą needle bearing Ą

planet gear Ą washer .
Before assembling washer, paste oil, spread
grease on needle bearing.

15L7ADA125

 Fix snap ring.

15L7ADA126

(5) Assemble of hub sub assembly

Η Paste loctite #5127 on axle housing.

15L7ADA127

Θ Assemble hub sub assembly.

Bolt : Assemble after spread loctite #277.
Confirm torque : 1170~1310kgfÂcm
ö Assemble hub sub assembly after support it by
lifting device as like the same way of
disassembling.

15L7ADA128

3-155
(6) The rest part assembly
Η Assemble O-ring and fitting bleeder for LH and RH.
Confirm torque : 380~420kgfÂcm

15L7ADA129

Θ Assemble bleeder and cap.

Screw : Assemble after spread loctite #577.
Confirm torque : 150~200kgfÂcm

15L7ADA130

Ι Assemble air breather.

15L7ADA131

Κ Assemble drain plug (magnetic).

Screw : Assemble after spread loctite #577.
Confirm torque : 700~900kgfÂcm

15L7ADA132

Λ Assemble drain plug (magnetic).

Screw : Assemble after spread loctite #577.
Confirm torque : 300~410kgfÂcm

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3-156
Μ Put in dipstick.
ö Fill axle oil as much as standard.
Standard between the upper limit and the lowest
limit. Figure DA134.

15L7ADA134

15L7ADA135

Ν Assemble bracket.
Bolt : Paste loctite #277.
Confirm torque : 610~650kgfÂcm

15L7ADA136

Ξ Finish drive axle assembly.

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3-157
(7) Functional test of hydraulic apply brake
ö The following procedure describes how to test the
hydraulic apply brake system only.
To perform this test, use a device that allows you to
observe possible leaks through oil seals and that
also allows you to verify that the piston return
system works correctly . For an accurate
evaluation, the device must allow piston
displacement of 0.4~0.6mm.
Η Brake bleeder valve while supplying hydraulic oil to
the pressure inlet. Pump oil through the brake until
oil coming out of the bleeder does not contain air
bubbles.
Close the brake bleeder valve.
Θ Actuate the piston at least five times with 60 bar.
Check for leaks and free movement of piston. Refer
to step 7).
Ι If you find a leak : Disassemble the hub sub
assembly. Determine the cause of the leak and
correct the problem. Check the seal surfaces for
sharp edges, nicks and burrs.
Κ Wait five minutes. Apply 60 bar to the piston and
lock pressure on. Pressure must not drop after one
minute.
Λ If pressure drops off : Disassemble the hub sub
assembly. Determine the cause of the leak and
correct the problem. Repeat step 1) - 5).
ö You must check that the brake completely releases
after you apply the brake.
Do not operate the brake system with the brake
partially released. Damage to brake components
can result.

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