Assembly

GEAR AND HUB ASSEMBLY

NOTE: Position open ends of springs 120° apart.
(A): 1st gear side
(B): 2nd gear side
(C): Flush surface
(D): Stepped surface








DRIVEN GEAR ASSEMBLY


NOTE: Assemble a driven shaft and 1st driven gear that select for

1. Install 1st driven gear, 1st-2nd baulk ring and gear and hub assembly onto driven shaft.

NOTE: Take care to install gear hub in proper direction.





2. Install 2nd driven gear bushing onto driven shaft using Special Tool (ST) 1, ST2 and press.

ST1 499277200 Installer, or equivalent.
ST2 499587000 Installer, or equivalent.

CAUTION: Attach a cloth (1) to the end of driven shaft to prevent damage.





3. Install 2nd driven gear, 1st-2nd baulk ring and insert onto driven shaft. After installing key on driven shaft, install 3rd-4th driven gear using ST and press.

ST 499277200 Installer, or equivalent.

NOTE: Align groove in baulk ring with insert.





4. Install a set of roller bearings (42 x 74 x 40) onto the driven shaft using ST and press.

ST 499277200 Installer, or equivalent.





5. Position woodruff key in groove on the rear of driven shaft. Install 5th driven gear onto drive shaft using ST and press.

ST 499277200 Installer, or equivalent.





6. Install lock washer (42 x 53 x 2). Install lock nut (42 x 13) and tighten to the specified torque using ST.

ST 499987300 Socket Wrench (50), or equivalent.

Tightening torque: 265 +/- 10 Nm (195 +/- 7 ft. lbs.).

NOTE:
- Stake lock nut at two points.





- Using spring balancer, check that starting torque of roller bearing (2) is 0.1 to 1.5 Nm (0.9 to 13.0 inch lbs.)..

DRIVE PINION SHAFT
1. Install roller bearing onto drive pinion. Install washer (1) (33 x 50 x 5) using Special Tools (ST) 1, ST2 and press.

ST1 499277100 Bush 1-2 Installer, or equivalent.
ST2 499277200 Installer, or equivalent.





NOTE: When installing roller bearing (2), note its directions (front and rear) because knock pin hole (3) in outer race is offset.





2. Install thrust bearing (33 x 50 x 3) and needle bearing (30 x 37 x 23). Install driven shaft assembly (4).





3. Install drive pinion collar (5), needle bearing (6) (25 x 30 x 20), adjusting washer No. 2 (7) (25 x 36 x 4), thrust bearing (8) (25 x 37.5 x 3), adjusting washer No. 1 (9) (25 x 36 x t) and differential bevel gear sleeve in that order.

NOTE: Be careful because spacer must be installed in proper direction.
(A): Driven shaft
(B): Driven pinion shaft





ADJUSTMENT OF THRUST BEARING PRELOAD
1. After completing steps 1 through 3 in DRIVE PINION SHAFT, select adjusting washer No. 2 so that dimension (H) is zero through visual check. Position washer (18.3 x 30 x 4)and lock washer (18 x 30 x 2) and install lock nut (18 x 13.5).





2. Using Special Tool (ST) 1, ST2 and ST3, tighten lock nut to the specified torque.

ST1 899884100 Holder, or equivalent.
ST2 498427100 Stopper, or equivalent.
ST3 899988608 Socket Wrench (27), or equivalent.

Tightening torque: 118 +/- 8 Nm (86.8 +/- 5.8 ft. lbs.).





3. After removing ST2, measure starting torque using torque driver.

ST1 899884100 Holder, or equivalent.
ST3 899988608 Socket Wrench (27), or equivalent.

Starting torque: 0.5 +/- 0.2 Nm (0.4 +/- 0.2 ft. lbs.).








4. If starting torque is not within specified limit, select new adjusting washer No. 1 (2) and recheck starting torque.











5. If specified starting torque range cannot be obtained when a No. 1 (2) adjusting washer is used, then select a suitable No. 2 (3) adjusting washer from those listed in the following table. Repeat steps 1 through 4 to adjust starting torque.
6. Recheck that starting torque is within specified range, then clinch lock nut at four positions.