1. Inspect pack clearance of reverse clutch

(A) install the intermediate shaft and needle roller bearing onto the transaxle rear cover.
(B) using a dial indicator, measure the reverse clutch pack clearance while applying and releasing compressed air (392 kpa, 4.0 Kgf/cm2, 57 psi).
Pack clearance: 0.60 To 0.82 Mm (0.02362 To 0.03228 In.)V
If the pack clearance is not as specified, inspect the discs, plates and flange.
2. Inspect pack clearance of direct clutch and overdrive clutch

(a) Using a dial indicator, measure the direct clutch and overdrive clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).
Pack clearance: 0.61 to 0.83 mm (0.02401 to 0.03268 in.)
If the pack clearance is not as specified, inspect the discs, plates and flange.
3. INSPECT DIRECT MULTIPLE DISC CLUTCH DISC

(a) Check if the sliding surfaces of the disc, plate and flange are worn or burnt.
If necessary, replace them.
HINT:
4. INSPECT OVERDRIVE DIRECT CLUTCH DISC

(a) Check if the sliding surface of the disc, plate and flange are worn or burnt.
If necessary, replace them.
HINT:
5. INSPECT OVERDRIVE CLUTCH RETURN SPRING SUB-ASSEMBLY

(a) Using vernier calipers, measure the free length of the spring together with the spring seat.
Standard free length: 25.91 mm (1.0201 in.)
6. INSPECT PACK CLEARANCE OF REVERSE CLUTCH

(a) Install the intermediate shaft onto the transaxle rear cover.
(b) Using a dial indicator, measure the direct clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).
Clearance: 0.60 to 0.82 mm (0.02362 to 0.03228 in.)
If the pack clearance is less than the minimum, parts may have been assembled incorrectly, so check and reassemble again. If the clearance is not as specified, select another flange.
HINT: There are 7 flanges of different thickness.
Flange thickness: mm (in.)
7. INSPECT PACK CLEARANCE OF DIRECT CLUTCH AND OVERDRIVE CLUTCH
(a) Using a dial indicator, measure the direct clutch & overdrive clutch pack clearance while applying and releasing compressed air (392 kPa, 4.0 kgf/cm2, 57 psi).
psi).
Clearance: 0.61 to 0.83 mm (0.02401 to 0.03268 in.)
If the pack clearance is less than the minimum, parts may have been assembled incorrectly, so check and reassemble again. If the clearance is not as specified, select another flange.
HINT: There are 7different thicknesses of flanges available
Flange thickness: mm (in.)

(b) Check that the disc rotates when rotating the disc after inserting the rear planetary sun gear.

NOTICE: Do not place the rear planetary sun gear in a vise.
Disassembly
ReassemblyHeadlight leveling switch
ON-VEHICLE INSPECTION
1. HEADLIGHT LEVELING SWITCH
Connect the battery positive (+) lead to the terminal
1 and the battery negative (-) lead to the terminal 5.
Measure the resistance between the terminal 4 and
the battery negative (-) lead when headlight leveling
switch ...
Folding and extending the mirrors
Manual type
Push the mirror back in the direction
of the vehicle’s rear.
Power type
Press the switch.
Folding
Extending
...
When towing full-time 4wd vehicles
Use one of the methods shown below to tow the
vehicle.
If the vehicle has trouble with the chassis or drive
train, use method 1 (flat bed truck).
WHEN TOWING FULL-TIME 4WD VEHICLES
NOTICE: Do not use any towing method other than those shown above.
The towing methods shown b ...