Drive Pinion Assembly
A: DISASSEMBLY1. Drive Pinion Shaft
1. Straighten lock nut at staked portion. Remove the lock nut using ST1, ST2 and ST3.
ST1 899984100 HOLDER
ST2 498427100 STOPPER
ST3 899988608 SOCKET WRENCH
2. Withdraw drive pinion from driven shaft.
Remove differential bevel gear sleeve (I), adjusting washer No. 1 (2) (25 x'37.5 x t), adjusting washer No. 2 4) (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 (0) (33 x 50 x 3).
3. Remove roller bearing and washer (33 x 50 x 5) using ST and press.
ST 498077000 REMOVER
CAUTION: Do not reuse roller bearing.
2. Driven Gear Assembly
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-4th driven gear using SST1 and SST2.
SST1 499757002 SNAP RING PRESS
SST2 899714110 REMOVER
5. Remove the key.
6. Remove 2nd driven gear (1), inner baulk ring (2), synchro cone (3) and outer baulk ring (4).
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
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
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 (1) 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 (1), inner baulk ring (2), synchro cone (3), outer baulk ring (4) and insert onto driven shaft.
5. After installing key on driven shaft, install 3rd-4th driven gear using SST and press.
SST 499277200 INSTALLER
NOTE:
Align groove in baulk ring with insert.
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 (2) is 0.1 to 1.5 Nm (1 to 15 kg-cm, 0.9 to 13.0 inch lbs.).
3. Drive Pinion Shaft
1. Install roller bearing onto drive pinion. Install washer 1) (33 x 50 x 5) using ST1, ST2 and press.
ST1 499277100 BUSH 1-2 INSTALLER
ST2 499277200 INSTALLER
NOTE: When installing roller bearing note its directions (front and rear) because knock pin hole (I in outer race is off set.
2. Install thrust bearing (33 x 50 x 3) and needle bearing (30 x 37 x 23). Install driven shaft assembly %.
3. Install drive pinion collar (5), needle bearing * (25 x 30 x 20), adjusting washer No. 2 1) (25 x 36 x 4), thrust bearing (8) (25 x 37.5 x 3), adjusting washer No. 1 4 (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 a 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 ST1, ST2 and ST3, tighten lock nut to the specified torque.
ST1 899884100 HOLDER
ST2 498427100 STOPPER
ST3 899988608 SOCKET WRENCH (27)
Tightening torque: 118 ± 8 Nm (86.8 ± 5.8 ft. lbs.)
3. After removing ST2, measure starting torque using torque driver.
ST1 899884100 HOLDER
ST3 899988608 SOCKET WRENCH (27)
Starting torque: 54 ± 25 Nm (40 ± 18 ft. lbs.)
4. If starting torque is not within specified limit, select new adjusting washer No. 1 (9) 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 1 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.