Part 2

ASSEMBLY





1. Press on 1st main gear, 1st baulk ring and 1st & 2nd synchronizer hub.
- Pay attention to direction of 1st & 2nd synchronizer hub.





2. Select proper snap ring of 1st & 2nd synchronizer hub to minimize clearance of groove and then install it.
Allowable clearance of groove: 0 - 0.1 mm (0 - 0.004 inch)
Snap ring of 1st & 2nd synchronizer hub: Refer to Application and ID.





3. Install 2nd synchronizer cone, inner & outer baulk rings. Insert springs and 1st & 2nd coupling sleeve.
4. Install 2nd main gear.
- Ensure four protrusions of 2nd synchronizer cone are set in holes of 2nd main gear.





5. Press on 3rd main gear.
6. Press on 4th main gear.





7. Press on 5th main gear.
8. Select proper snap ring of 5th main gear to minimize clearance of groove and then install it.
Allowable clearance of groove: 0 - 0.15 mm (0 - 0.0059 inch)
Snap ring of 5th main gear: Refer to Application and ID.





9. Press on thrust washer and press on mainshaft rear bearing.
10. Press on mainshaft front bearing.
11. Measure gear end play as a final check. Refer to DISASSEMBLY.

Final Drive
DISASSEMBLY
- RS5F150A -





1. Remove final gear.
2. Remove speedometer drive gear by cutting it.
3. Press out differential side bearings.
- Be careful not to mix up the right and left bearings.





4. Drive out retaining pin and draw out pinion mate shaft.
5. Remove pinion mate gears and side gears.

- RS5F50V -





1. Remove final gear.





2. Press out differential side bearings.





3. Remove speedometer drive gear.





4. Remove viscous coupling.





5. Separate differential cases. Make paint marks to identify their original positions.
6. Remove pinion mate shaft with gears.

INSPECTION
Gear, washer, shaft and case





- Check mating surfaces of differential case, viscous coupling, side gears and pinion mate gears.
- Check washers for wear.

Viscous coupling





- Check case for cracks.
- Check silicone oil for leakage.

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. Attach side gear thrust washers to side gears, then install pinion mate washers and pinion mate gears in place.





2. Insert pinion mate shaft.
- When inserting, be careful not to damage pinion mate thrust washers.

- RS5F50A -
3. Measure clearance between side gear and differential case with washers following the procedure below:
a. Set Tool and dial indicator on side gear.





b. Move side gear up and down to measure dial indicator deflection. Always measure indicator deflection on both side gears.
Clearance between side gear and differential case with washers: 0.1 - 0.2 mm (0.004 - 0.008 inch)





c. If not within specification, adjust clearance by changing thickness of side gear thrust washers.
Side gear thrust washer: Refer to Application and ID.





4. Install retaining pin.
- Make sure that retaining pin is flush with case.





5. Install final gear.
6. Install speedometer drive gear.





7. Press on differential side bearings.

- RS5F50V -
3. Measure clearance between side gear and differential case & viscous coupling with washers using the following procedure:

Differential case side





a. Set tool on the differential case and lock gauging cylinder in place with set screw.





b. Install gauging plunger into cylinder.





c. Install pinion mate gears and side gear with thrust washer on differential case.
d. Set tool and allow gauging plunger to rest on side gear thrust washer.
e. Measure gap between plunger and cylinder. This measurement should give exact clearance between side gear and differential case with washers.
Standard clearance: 0.1 - 0.2 mm (0.004 - 0.008 inch)
f. If not within specification adjust clearance by changing thickness of side gear thrust washer.
Side gear thrust washers for differential case side: Refer to Application and ID.

Viscous coupling side
a. Place side gear and thrust washer on pinion mate gears installed on differential case.
b. Measure dimension X.
- Measure dimension X in at least four places.





a. Set tool on viscous coupling and lock gauging cylinder in place with set screw.





b. Install gauging plunger into cylinder.





c. Install pinion mate gears and side gears with original washers on differential cases.
Align paint marks.
d. Tighten differential case bolts.
e. Set tool and allow plunger to rest on side gear thrust washer.
f. Measure gap between plunger and cylinder. This measurement should give exact clearance between side gear and differential case with washers.
Standard clearance: 0.1 - 0.2 mm (0.004 - 0.008 inch)
g. If not within specification, adjust clearance by changing thickness of side gear thrust washer.
Side gear thrust washers for viscous coupling side: Refer to Application and ID.





4. Install viscous coupling.





5. Install speedometer drive gear on differential case.
- Align the projection of speedometer drive gear with the groove of differential case.





6. Press differential side bearings on differential case.





7. Install final gear and tighten fixing bolts in a crisscross pattern.

Shift Control Components
INSPECTION





- Check contact surface and sliding surface for wear, scratches, projections or other damage.

Case Components
REMOVAL AND INSTALLATION





Input shaft oil seal





- Apply multi-purpose grease to seal lip of oil seal before installing.

Mainshaft front bearing outer race





- Extract the oil channel and remove the mainshaft front bearing outer race.
Mainshaft rear bearing outer race
Refer to ADJUSTMENT. Adjustment
Differential side bearing outer race