Part 2 of 3

2. Install 2nd driven gear bushing onto driven shaft using SST1, SST2 and press.
SST1 499277200 INSTALLER
SST2 499587000 INSTALLER

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 SST and press.
SST 499277200 INSTALLER
Align groove in baulk ring with insert.





4. Install a set of roller bearings (42 x 74 x 40) onto the driven shaft using SST and press.
SST 499277200 INSTALLER





5. Position woodruff key in groove on the rear of driven shaft. Install 5th driven gear onto drive shaft using SST and press.
SST 499277200 INSTALLER





6. Install lock washer (42 x 53 x 2). Install lock nut (42 x 13) and tighten to the specified torque using SST.
SST 499987300 SOCKET WRENCH (50)

Tightening torque:
265 ± 10 Nm (27 ± 1 kg-m, 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 (1 to 15 kg-cm, 0.9 to 13.0 inch lbs.).








2. Driven Gear Assembly (2500 cc Model)
Assemble a driven shaft and 1st driven gear that select for adjustment the proper radial clearance.
1. Install sub gear to 1st driven gear.
2. Install 1st driven gear, 1st baulk ring, gear and hub assembly onto driven shaft.

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





3. Install 2nd driven gear bushing onto driven shaft using SST1, SST2 and press.
SST1 499277200 INSTALLER
SST2 499587000 INSTALLER

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

NOTE: When press fitting, align oil holes of shaft and bush.





4. Install 2nd driven gear, inner baulk ring, synchro cone, outer baulk ring and insert onto driven shaft.
(A) 2nd driven gear
(B) Inner baulk ring
(C) Synchro cone
(D) Outer baulk ring





5. After installing key on driven shaft, install 3rd-4th driven gear using SST and press.

NOTE: Align groove in baulk ring with insert.

SST 499277200 INSTALLER





6. Install a set of roller bearings (42 x 74 x 40) onto the driven shaft using SST and press.
SST 499277200 INSTALLER





7. Position woodruff key in groove on the rear of driven shaft. Install 5th driven gear onto drive shaft using SST and press.
SST 499277200 INSTALLER





8. Install lock washer (42 x 53 x 2). Install lock nut (42 x 13) and tighten to the specified torque using SST.
SST 499987300 SOCKET WRENCH (50)

Tightening torque:
265 ± 10 Nm(27 ± 1 kg-m, 195 ± 7 ft. lbs.)





NOTE:
^ Stake lock nut at two points.
^ Using spring balancer, check that starting torque of roller bearing is 0.1 to 1.5 Nm (0.01 to 0.15 kg-m, 0.07 to 1.1 ft. lbs.).

3. Drive Pinion Shaft





1. Install roller bearing onto drive pinion. Install washer (1) (33 x 50 x 5) using SST1, SST2 and press.
SST1 499277100 BUSH 1-2 INSTALLER
SST2 499277200 INSTALLER





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

4. Adjustment Of Thrust Bearing Preload





1. After completing the preceding steps 1. through 3., 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 SST1, SST2 and SST3, tighten lock nut to the specified torque.
SST1 899884100 HOLDER
SST2 498427100 STOPPER
SST3 899988608 SOCKET WRENCH (27)

Tightening torque:
118 ± 8 Nm (12 ± 0.8 kg-m, 86.8 ± 5.8 ft. lbs.)





3. After removing SST2, measure starting torque using torque driver.
SST1 899884100 HOLDER
SST3 .899988608 SOCKET WRENCH (27)

Starting torque:
0.5 ± 0.2 Nm (0.055 ± 0.025 kg-m, 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.

4. MAIN SHAFT ASSEMBLY
A: Disassembly
1. 2200 cc Model





1. Put vinyl tape around main shaft splines to protect oil seal from damage. Then pull out oil seal and needle bearing by hand.
2. Remove lock nut from transmission main shaft assembly.

NOTE: Remove caulking before taking off lock nut.

Special Service Tool(SST)1 498937000 TRANSMISSION HOLDER
(SST)2 499987003 SOCKET WRENCH (35)





3. Remove insert stopper plate (1), sleeve and hub assembly No. 2, baulk ring (3), 5th drive gear (4), and needle bearing (5) (32 x 36 x 25.7).





4. Using SST1, SST2 and a press, remove:
- 5th needle bearing inner race (1)
- 5th gear thrust washer (2)
- Ball bearing (3) (25.5 x 65 x 31)
- 4th gear thrust washer (4)
- 4th drive gear (5)
- Sleeve and hub assembly (6)
- Baulk ring (7)
- 4th needle bearing (8)
- 4th needle bearing inner race (9)
- 3rd drive gear (10)
SST1 899864100 REMOVER
SST2 899714110 REMOVER

NOTE:
Replace sleeve and hub with new ones. Do not attempt to disassemble because they must engage at a specified point. If they should be disassembled, mark engagement point on splines beforehand.

1. 2500 cc Model





1. Put vinyl tape around main shaft splines to protect oil seal from damage. Then pull out oil seal and needle bearing by hand.
2. Remove lock nut from transmission main shaft assembly.

NOTE: Remove caulking before taking off lock nut.

Special Service Tool(SST)1 498937000 TRANSMISSION HOLDER
(SST)2 499987003 SOCKET WRENCH (35)





3. Remove insert stopper plate, sleeve and hub assembly No. 2, baulk ring, 5th drive gear, and needle bearing.
(A) Insert stopper plate
(B) Sleeve and hub assembly No. 2
(C) Baulk ring
(D) 5th drive gear
(E) Needle bearing (32 x 36 x 25.7)





4. Using SST1 and SST2, remove the rest of parts.

NOTE: Replace sleeve and hub with new ones. Do not attempt to disassemble because they must engage at a specified point. If they should be disassembled, marking engagement point on splines beforehand.

SST1 899864100 REMOVER
SST2 899714110REMOVER

B: Assembly
2200 cc Model





1. Assemble sleeve and hub assembly for 3rd-4th and, 5th and high-low synchronizing.

NOTE:
Position open ends of spring 120° apart.

(A): Two holes for discrimination (3rd-4th hub)





(B): One hole for discrimination (5th hub)
2. Install 3rd drive gear, baulk ring, and sleeve and hub assembly for 3rd-4th needle bearing (32 x 36 x 25.7) on transmission main shaft.

NOTE:
Align groove in baulk ring with shifting insert.





3. Install 4th needle bearing race (1) onto transmission main shaft using SST1, SST2 and a press.
SST1 899714110 REMOVER
SST2 499877000 RACE 4-5 INSTALLER





4. Install baulk ring, needle bearing (32 x 30 x 25.7), 4th drive gear and 4th gear thrust washer to transmission main shaft.

NOTE:
Face thrust washer in the correct direction.

(a): Groove
(b): 4th gear side





5. Drive ball bearing (1) onto the rear section of transmission main shaft using SST1, SST2 and a press.
SST1 899714110 REMOVER
SST2 499877000 RACE 4-5 INSTALLER





6. Using the same tools as in step 5. above, install the following parts onto the rear section of transmission main shaft.
- 5th gear thrust washer

NOTE: Face thrust washer in the correct direction.

(C): Face this surface to 5th gear side.
SST1 899714110 REMOVER
SST2 499877000 RACE 4-5 INSTALLER
- 5th needle bearing race





7. Install the following parts to the rear section of transmission main shaft.
- Needle bearing (32 x 36 x 25.7)
- 5th drive gear
- Baulk ring
- Sleeve (A) and hub assembly
- Insert stopper plate (B)
- Lock washer (C) (22 x 38 x 2)
- Tighten lock nuts (D) (22 x 13) to the specified torque using SST1 and SST2.
SST1 499987003 SOCKET WRENCH (35)
SST2 498937000 TRANSMISSION HOLDER

NOTE:
^ Align groove (E) in baulk ring with shifting insert.
^ Be sure to fit pawl (F) of insert stopper plate into 4 mm (0.16 inch) dia. hole in the boss section of synchronizer hub.
^ Secure lock nuts in two places after tightening.

Tightening torque:
118 ± 6 Nm (12.0 ± 0.6 kg-m, 86.8 ± 4.3 ft. lbs.)

2500 cc Model





1. Assemble sleeve and hub assembly for 3rd-4th and, 5th synchronizing.

NOTE: Position open ends of spring 120° apart.

(A) Two holes for discrimination (3rd-4th hub)
(B) One hole for discrimination (5th hub)





2. Install 3rd drive gear, outer baulk ring, synchro cone, inner baulk ring, sleeve and hub assembly for 3rd needle bearing on transmission main shaft.

NOTE: Align groove in baulk ring with insert key.

(A) 3rd needle bearing (32 x 36 x 25.7)
(B) 3rd drive gear
(C) Inner baulk ring
(D) Synchro cone
(E) Outer baulk ring
(F) Sleeve and hub ASSY





3. Install 4th needle bearing race onto transmission main shaft using SST1, SST2 and a press.
SST1 899714110 REMOVER
SST2 499877000 RACE 4-5 INSTALLER





4. Install baulk ring, needle bearing (32 x 30 x 25.7), 4th drive gear and 4th gear thrust washer to transmission main shaft.
(A) Groove
(B) 4th gear side





5. Drive ball bearing onto the rear section of transmission main shaft using SST1, SST2 and a press.
SST1 899714110 REMOVER
SST2 499877000 RACE 4-5 INSTALLER





6. Using SST1 and SST2, install the 5th gear thrust washer and 5th needle bearing race onto the rear section of transmission main shaft.

NOTE: Face thrust washer in the correct direction.

SST1 899714110 REMOVER
SST2 499877000 RACE 4-5 INSTALLER
(A) Face this surface to 5th gear side.





7. Install the following parts to the rear section of transmission main shaft.

NOTE:
^ Align groove in baulk ring with shifting insert.
^ Be sure to fit pawl of insert stopper plate into 4 mm (0.16 inch) dia. hole in the boss section of synchronizer hub.

(A) Needle bearing (32 x 36 x 25.7)
(B) 5th drive gear
(C) Baulk ring
(D) Sleeve and hub assembly
(E) Insert stopper plate
(F) Lock washer (22 x 38 x 2)
(G) Lock nut

8. Tighten lock nuts (22 x 13) to the specified torque using SST1 and SST2.

NOTE: Secure lock nuts in two places after tightening.

SST1 499987003 SOCKET WRENCH (35)
SST2 498937000 TRANSMISSION HOLDER

Tightening torque:
118 ± 6 Nm (12.0 ± 0.6 kg-m, 86.8 ± 4.3 ft. lbs.)

5. TRANSFER CASE AND EXTENSION
A: Removal





1. Remove transfer cover (1).
2. Remove shifter fork screw (2) which secures selector arm to shifter arm.
3. Remove transfer case (4) with extension assembly (3).

B.: Disassembly
1. Separation Of Transfer Case And Extension Assembly





1. Separate transfer case (1) and extension assembly (2) .
2. Remove transfer driven gear (3) and center differential (4) as a set.
3. Remove thrust washer (5) (52 x 61 x t).

2. Transfer Case





1. Remove neutral switch (1).

NOTE:
Before removing shifter arm, disconnect neutral switch.

2. Draw out shifter arm (2) and remove selector arm (3).
3. Remove plug (4), spring (5) and reverse check ball (6).