Part 1 of 3
TRANSMISSION CASEA: Disassembly
Separation Of Transmission
1. Remove transfer cover.
2. Remove shifter fork screw which secures selector arm to shifter arm.
3. Remove transfer case with extension assembly.
4. Remove clutch release lever and bearing.
Mechanical application type.
Hydraulic application type
(A) Clutch release lever
(B) Clutch release bearing
5. Remove bearing mounting bolts.
6. Remove main shaft rear plate.
(A) Main shaft rear plate
(B) Main shaft ASSY
7. Separating transmission case
1. Put vinyl tape around splines of right and left axle drive shafts to prevent damage to oil seals.
2. Separate transmission case into right and left cases by loosening seventeen coupling bolts and nuts.
8. Remove drive pinion shaft assembly from left side transmission case.
NOTE: Use a hammer handle, etc. to remove if too tight.
9. Remove main shaft assembly.
(A) Drive pinion shaft ASSY
(B) Main shaft ASSY
10. Remove differential assembly.
CAUTION:
^ Be careful not to confuse right and left roller bearing outer races.
^ Be careful not to damage retainer oil seal.
B: Assembly
Combination Of Transmission Case
1. Alignment marks/numbers on hypoid gear set
The upper number on driven pinion is the match number for combining it with hypoid driven gear. The lower number is for shim adjustment. If no lower number is shown, the value is zero. The number on hypoid driven gear indicates a number for combination with drive pinion.
2. Adjustment of drive pinion shim
1. Place drive pinion shaft assembly on right hand transmission main case without shim and tighten bearing mounting bolts.
2. Inspection and adjustment of Special Service Tool (SST)
NOTE:
^ Loosen the two bolts and adjust so that the scale indicates 0.5 correctly when the plate end and the scale end are on the same level.
^ Tighten the two bolts.
(SST) 499917500 DRIVE PINION GAUGE ASSY
(A) Plate
(B) Scale
3. Position the SST by inserting the knock pin of SST into the knock hole in the transmission case.
SST 499917500 DRIVE PINION GAUGE ASSY
4. Slide the drive pinion gauge scale with finger tip and read the value at the point where it matches with the end face of drive pinion.
SST 499917500 DRIVE PINION GAUGE ASSY
(C) Adjust clearance to zero without shim.
5. The thickness of shim shall be determined by adding the value indicated on drive pinion to the value indicated on the SST. (Add if the number on drive pinion is prefixed by + and subtract if the number is prefixed by -.)
SST 499917500 DRIVE PINION GAUGE ASSY
6. Select one to three shims from the next table for the value determined as described above and take a shim thickness which is closest to the said value.
3. Install differential assembly on left hand transmission case.
CAUTION: Be careful not to fold the sealing lip of oil seal.
NOTE:
Wrap the left and right splined sections of axle shaft with vinyl tape to prevent scratches.
4. Install needle bearing and oil seal onto the front of transmission main shaft assembly, and position in left side transmission case.
CAUTION:
^ Wrap clutch splined section with vinyl tape to prevent damage to oil seal.
^ Apply grease (Unilube #2 or equivalent) to the sealing lip of oil seal.
NOTE:
^ Align the end face of seal with surface "A" of left side transmission main case when installing oil seal.
^ Be careful not to drop oil seal when installing right side transmission main case.
^ Make sure straight pin is positioned in hole in needle bearing's outer race.
5. Install drive pinion shaft assembly with shims selected before into transmission case.
NOTE: Ensure that the knock pin of the case is fitted into the hole in the bearing outer race.
(A) Drive pinion shaft ASSY
(B) Transmission case
6. Selection of suitable 1st-2nd, 3rd-4th and 5th shifter fork
Set transmission main shaft assembly and drive pinion shaft assembly in position (so there is no clearance between the two when moved all the way to the front). Select suitable 1st-2nd, 3rd-4th and 5th shifter fork so that coupling sleeve and reverse driven gear are positioned in the center of their synchronizing mechanisms.
1st and 2nd clearance
a: 9.5 mm (0.374 inch)
b: 9.5 mm (0.374 inch)
(A) 1st driven gear
(B) Reverse driven gear
(C) 2nd driven gear
3rd and 4th clearance
a: 9.3 mm (0.366 inch)
b: 9.3 mm (0.366 inch)
(A) 3rd drive gear
(B) Coupling sleeve
(C) 4th drive gear
5th clearance
a: 9.3 mm (0.366 inch)
(A) 5th drive gear
(B) Coupling sleeve
7. Inspection of rod end clearance Measure rod end clearances A and B. If any clearance is not within specifications, replace rod or fork as required,
8. Combination of transmission case
1. Wipe off grease, oil and dust on the mating surfaces of transmission cases with white gasoline, and apply liquid gasket, and then put case right side and left side together.
Liquid gasket:
THREE BOND 1215 or equivalent
2. Tighten 17 bolts with bracket, clip, etc. as shown in the figure.
NOTE:
^ Insert bolts from the bottom and tighten nuts at the top.
^ Put cases together so that drive pinion shim is not caught up in between.
^ Confirm that speedometer gear is meshed.
Tightening torque:
10 mm bolt (No. <1>-<4>, <16>, <17>)
39 ± 3 Nm (4.0 ± 0.3 kg-m, 28.9 ± 2.2 ft. lbs.)
8 mm bolt (No. <5>-<15>)
25 ± 2 Nm (2.5 ± 0.2 kg-m, 18.1 ± 1.4 ft. lbs.)
9. Tighten ball bearing attachment bolts.
Tightening torque: 29 ± 3 Nm (3.0 ± 0.3 kg-m, 21.7 ± 2.2 ft. lbs.)
10. Backlash adjustment of hypoid gear and preload adjustment of roller bearing
NOTE: Support drive pinion assembly with SST.
SST 498427100 STOPPER
1. Place the transmission with case left side facing downward and put SST1 on bearing cup.
2. Screw retainer assembly into left case from the bottom with SST2. Fit SST3 on the transmission main shaft. Shift gear into 4th or 5th and turn the shaft several times. Screw in the retainer while turning SST3 until a slight resistance is felt on SST2.
This is the contact point of hypoid gear and drive pinion shaft. Repeat the above sequence several times to ensure the contact point.
SST1 399780104 WEIGHT
SST2 499787000 WRENCH ASSY
SST3 499927100 HANDLE
3. Remove weight and screw in retainer without O-ring on the upper side and stop at the point where slight resistance is felt.
NOTE:
At this point, the backlash between the hypoid gear and drive pinion shaft is zero.
SST 499787000 WRENCH ASSY
4. Fit lock plate. Loosen the retainer on the lower side by 1-1/2 teeth of lock plate and turn in the retainer on the upper side by the same amount in order to obtain the backlash.
NOTE:
The notch on the lock plate moves by 112 tooth if the plate is turned upside down.
5. Turn in the retainer on the upper side additionally by 1 tooth in order to apply preload on taper roller bearing.
6. Tighten temporarily both the upper and lower lock plates and mark both holder and lock plate for later readjustment.
7. Turn transmission main shaft several times while tapping around retainer lightly with plastic hammer.
8. Set SST1 and SST2. Insert the needle through transmission oil drain plug hole so that the needle comes in contact with the tooth surface at a right angle and check the backlash.
SST1 498247001 MAGNET BASE
SST2 498247100 DIAL GAUGE
Backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)
NOTE:
^ If backlash is outside specified range, adjust it by turning holder in right side case.
^ Each time holder rotates one tooth, backlash changes by 0.05 mm (0.0020 inch).
9. Check tooth contact of hypoid gear as follows: Apply a uniform thin coat of red lead on both tooth surfaces of 3 or 4 teeth of the hypoid gear. Move the hypoid gear back and forth by turning the transmission main shaft until a definite contact pattern is developed on hypoid gear, and judge whether face contact is correct. If it is incorrect, make the following correction.
- Tooth contact is correct.
(A) Toe
(B) Coast side
(C) Heel
(D) Drive side
- Backlash is excessive.
To reduce backlash, loosen holder on the upper side (case right side) and turn in the holder on the lower side (case left side) by the same amount.
- Backlash is insufficient.
To increase backlash, loosen holder on the lower side (case left side) and turn in the holder on the upper side (case right side) by the same amount.
- The drive pinion shim selected before is too thick. Reduce its thickness.
- The drive pinion shim selected before is too thin. Increase its thickness.
11. After checking the tooth contact of hypoid gears, remove the lock plate. Then loosen retainer until the O-ring groove appears. Fit O-ring into the groove and tighten retainer into the position where retainer has been tightened in.
Tighten lock plate.
NOTE: Carry out this job on both upper and lower retainers.
Tightening torque:
25 ± 3 Nm (2.5 ± 0.3 kg-m, 18.1 ± 2.2 ft. lbs.)
(A) Lock plate
(B) Retainer
(C) Transmission case
12. Selecting of main shaft rear plate
Using SST, measure the amount A of ball bearing protrusion from transmission main case surface and select the proper plate in the following table:
NOTE: Before measuring, tap the end of main shaft with a plastic hammer lightly in order to make the clearance zero between the main case surface and the moving flange of bearing.
SST 498147000 DEPTH GAUGE
13. Install clutch release lever and bearing.
Mechanical application type
Hydraulic application type
(A) Clutch release lever
(B) Clutch release bearing
3. DRIVE PINION ASSEMBLY
A: Disassembly
1. Drive Pinion Shaft
1. Straighten lock nut at staked portion. Remove the lock nut using Special Service Tool(SST)1, (SST)2 and SST3.
SST1 899884100 HOLDER
SST2 498427100 STOPPER
SST3 899988608 SOCKET WRENCH
2. Withdraw drive pinion from driven shaft.
Remove differential bevel gear sleeve (1), adjusting washer No. 1 (2) (25 x 37.5 x t), adjusting washer No. 2 (3) (25 x 37.5 x 4), thrust bearing (4) (25 x 37.5 x 3), needle bearing (5) (25 x 30 x 20), drive pinion collar (6), needle bearing (7) (30 x 37 x 23) and thrust bearing (8) (33 x 50 x 3).
3. Remove roller bearing and washer (33 x 50 x 5) using SST and press.
SST 498077000 REMOVER
CAUTION: Do not reuse roller bearing.
2. Driven Gear Assembly (2200 cc Model)
CAUTION:
Attach a cloth to the end of driven shaft (on the frictional side of thrust needle bearing) during disassembly or reassembly to prevent damage.
1. Straighten lock nut at staked portion. Remove the lock nut using SST1 and SST2.
SST1 499987300 SOCKET WRENCH (50)
SST2 899884100 HOLDER
2. Remove 5th driven gear using SST.
SST 499857000 5TH DRIVEN GEAR REMOVER
3. Remove woodruff key.
4. Remove roller bearing (42 x 74 x 40), 3rd and 4th driven gear using SST1 and SST2.
SST1 499757002 SNAP RING PRESS
SST2 899714110 REMOVER
5. Remove the key.
6. Remove 2nd driven gear assembly.
7. Remove 1st driven gear, 2nd gear bushing, gear and hub using SST1 and SST2.
Replace gear and hub if necessary. Do not attempt to disassemble if at all possible because they must engage at a specified point. If they have to be disassembled, mark the engaging point beforehand.
SST1 499757002 SNAP RING PRESS
SST2 899714110 REMOVER
8. Remove sub gears for 1st and 2nd driven gear.
2. Driven Gear Assembly (2500 cc Model)
CAUTION: Attach a cloth to the end of driven shaft (on the frictional side of thrust needle bearing) during disassembly or reassembly to prevent damage.
1. Straighten lock nut at staked portion. Remove the lock nut using Special Service Tool(SST)1 and (SST)2.
SST1 499987300 SOCKET WRENCH (50)
SST2 899884100 HOLDER
2. Remove 5th driven gear using SST.
SST 499857000 5TH DRIVEN GEAR REMOVER
3. Remove woodruff key.
4. Remove roller bearing (42 x 74 x 40), 3rd-4th driven gear using SST1 and SST2.
SST1 499757002 SNAP RING PRESS
SST2 899714110 REMOVER
5. Remove the key.
6. Remove 2nd driven gear, inner baulk ring, synchro cone and outer baulk ring.
(A) 2nd driven gear
(B) Inner baulk ring
(C) Synchro cone
(D) Outer baulk ring
7. Remove 1st driven gear, 2nd gear bushing, gear and hub using SST1 and SST2.
NOTE: Replace gear and hub if necessary. Do not attempt to disassemble if at all possible because they must engage at a specified point. If they have to be disassembled, mark the engaging point beforehand.
SST1 499757002 SNAP RING PRESS
SST2 899714110 REMOVER
8. Remove sub gear for 1st driven gear.
B: Assembly
1. Gear And Hub Assembly (2200 cc Model)
NOTE:
Position open ends of springs 120° apart.
(A): 1st gear side
(B): 2nd gear side
(C): Flush surface
(D): Stepped surface
1. Gear And Hub Assembly (2500 cc Model)
Assemble gear and hub assembly.
NOTE:
^ Use new gear and hub assembly, if gear or hub have been replaced.
^ Be sure the insert keys are correctly located in the insert key grooves inside the reverse driven gear.
(A) Key grooves
(B) Reverse driven gear
(A) 1st gear side
(B) 2nd gear side
(C) Flush surface
(D) Stepped surface
2. Driven Gear Assembly (2200 cc Model)
Assemble a driven shaft and 1st driven gear that select for adjustment the proper radial clearance.
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.