MR20DE engines (Manual transmission, CVT) and OR25DE (MCP) 1. Main gear assembly; 2. Central oil seal; 3. Solenoid wiring; 4. Electronically controlled clutch; 5. Coupling cover; 6. Bolt; 7. Bracket for connector; 8. Front oil seal; 9. Connecting flange; 10. Lock nut of the connecting flange; A. Oil seal lip.
Engine QR25DE (CVT) 1. Main gear assembly; 2. Central oil seal; 3. 4WD solenoid wiring; 4. Electronically controlled clutch; 5. Coupling cover; 6. Bolt; 7. Bracket for connector; 8. Front oil seal; 9. Connecting flange; 10. Lock nut of the connecting flange; A. Oil seal lip.
Removal and installation
Removal
1. Remove the rear driveshaft. See above.
2. Disconnect the connector from the 4WD solenoid.
3. Remove the bracket for the connector.
4. Apply an alignment mark to the threaded end of the electronic coupling. The mark must match the mark on the connecting flange.
Attention. Apply marks with paint. Be careful not to damage the electronically controlled clutch.
Note. When replacing an electronically controlled clutch, a mark is not required.
5. Using a flange wrench (suitable special tools) Unscrew the locknut of the connecting flange.
6. Remove the connecting flange.
7. Disconnect the electronic clutch breather hose from the clutch cover.
8. Remove the clutch cover with electronically controlled clutch from the final drive assembly.
9. Remove the electronic clutch from the clutch cover.
10. Remove the 4WD solenoid wiring harness.
11. Remove the front oil seal from the clutch cover using a flat blade screwdriver.
Attention. Do not damage the coupling cover.
12. Remove the center oil seal from the final drive assembly.
Installation
1. Using a punch (A) (special tool: ST35271000) press in the central oil seal (1), as shown in the picture.
Size «D»: 0.8-1.2 mm
Attention:
- Do not reuse the seal.
- When pressing, do not allow the oil seal to skew.
- Apply a universal grease remover to the seal lips and into the transmission oil around the seal circumference.
2. Connect the 4WD solenoid wiring harness to the electronic clutch.
3. Insert the electronically controlled clutch into the drive gear spline inside the differential housing.
Attention:
- Align the pin on the electronic clutch with the groove in the differential housing.
- Do not damage the central seal.
4. Insert the 4WD solenoid wiring guide into the differential housing.
5. Press in the front oil seal using drifts so that it is flush with the end surface of the coupling cover.
A. Punch (special tool KV38100200); V. Punch (special tool ST27861000)
Attention:
- Do not reuse the seal.
- When pressing, do not allow the oil seal to skew.
- Apply multi-purpose grease to the seal lips and into the transmission oil around the seal circumference.
6. Apply sealant to the contact surface of the coupling cover. Connect both ends of the strip with an overlap of at least 3 mm.
Attention. Remove old sealant from contact surfaces. Also remove any moisture, oil or foreign particles from them.
7. Install the clutch cover onto the final drive assembly with the arrow pointing upward and hand tighten the bolts at the locations shown in the illustration.
8. Tighten the specified bolts and the coupling cover mounting bolts to the specified torque.
9. Connect the electronic clutch breather hose to the clutch cover.
10. Install the bracket under the connector and tighten the bolts to the required torque.
11. Connect the wiring connector to the 4WD solenoid.
12. Attach the connecting flange.
Note. If you are reusing an electronically controlled coupling, align the mark on the coupling with the mark on the connecting flange, and then connect the connecting flange.
13. Using a flange wrench (suitable special tools) Place the locknut on the connecting flange and tighten to the required torque.
Attention. Do not reuse the connection flange locknut.
14. Check the runout of the connecting flange.
15. Attach the rear propeller shaft. See above.
16. If there was any oil leakage during removal, check the oil level after installation. See above.