Overhaul
1. MANUAL TRANSMISSION AND DIFFERENTIALA. General Specifications
2. SERVICE DATA
A: Transmission Gear Oil
B: Transmission Case Assembly
Drive Pinion Shim Adjustment
Hypoid Gear Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)
Selection Of Main Shaft Rear Plate
C: Drive Pinion Assembly
Preload adjustment of thrust bearing
Starting Torque: 0.3 - 0.8 Nm (3 - 8 kg-cm, 2.6 - 6.9 inch lbs.)
Assemble a driven shaft and 1st driven gear that are selected for the proper radial clearance adjustment.
D: Reverse Idler Gear
Adjustment of reverse idler gear position Reverse idler gear to transmission case (Left-Hand) wall clearance
6.0 - 7.5 mm (0.236 - 0.295 inch)
After installing a suitable reverse shifter lever, adjust reverse idler gear to transmission case wall clearance to within 0 to 0.5 mm (0 to 0.020 inch) using washers.
E: Shifter Fork And Rod
Select suitable shifter forks so that both coupling sleeve and reverse driven gear are positioned in the center of their synchromesh mechanisms.
Rod end clearance
1st-2nd-3rd-4th: 0.4 - 1.4 mm (0.016 - 0.055 inch)
3rd-4th-5th: 0.5 - 1.3 mm (0.020 - 0.051 inch)
F: Transfer Case
Neutral position adjustment
Reverse check plate adjustment
G: Extension
Snap Ring (Inner-72) To Ball Bearing Side Clearance: 0 - 0.15 mm (0 - 0.0059 inch)
Snap Ring (Outer-30) To Ball Bearing Side Clearance: 0 - 0.15 mm (0 - 0.0059 inch)
H: Extension Assembly
Thrust washer (52 x 61 x t) To Ball Bearing Side Clearance: 0.05 - 0.30 mm (0.0020 - 0.0118 inch)
I: Front Differential
Bevel Gear To Pinion Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)
Pinion Shaft To Axle Drive Shaft Clearance: 0 - 0.2 mm (0 - 0.008 inch)
J: Center Differential
Snap ring (Inner-110) to center differential case clearance: 0 - 0.15 mm (0 - 0.0059 inch)
Backlash Adjustment Axial Movement: 0.62 - 0.86 mm (0.0244 - 0.0339 inch)