Overhaul

MANUAL TRANSMISSION AND DIFFERENTIAL





A: SPECIFICATIONS

B: SERVICE DATA
1. 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

2. 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.

3. REVERSE IDLER GEAR





Adjustment of reverse idler gear position
Reverse idler gear to transmission case (LH) 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 O to 0.5 mm (0 to 0.020 inch) using washers.

4. 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
A: 1st-2nd - 3rd-4th 0.5 - 1.5 mm (0.020 - 0.059 inch)
B: 3rd-4th - 5th 0.6 - 1.4 mm (0.024 - 0.055 inch)

5. TRANSFER CASE








Neutral position adjustment





Reverse check plate adjustment.

6. EXTENSION ASSEMBLY (AWD Model)





Thrust washer (52 x 61 x t) to ball bearing side clearance: 0.05 - 0.30 mm (0.0020 - 0.0118 inch)





Thrust washer to center differential side clearance: 0.15 - 0.35 mm (0.0059 - 0.0138 inch)

7. 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)