Transmission Case
A: REMOVAL1. Remove the manual transmission assembly from vehicle.
2. Remove back-up light switch and neutral position switch.
3. Remove clutch release lever.
4. Remove transfer case and extension case assembly.
5. Remove bearing mounting bolts.
6. Remove main shaft rear plate.
7. Put vinyl tape around splines of right and left axle drive shafts to prevent damage to oil seal.
8. Separate transmission case into right and left cases by loosening coupling bolts and nuts.
B: INSTALLATION
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 and input shaft holder shim are not caught up in between.
^ Confirm that speedometer gear is meshed.
Tightening torque:
8 mm bolt: 25 Nm (2.5 kgf-m, 18.1 ft. lbs.)
10 mm bolt: 39 Nm (4.0 kgf-m, 28.9 ft. lbs.)
3. Tighten ball bearing attachment bolts.
Tightening torque: 29 Nm (3.0 kgf-m, 21.7 ft. lbs.)
4. Backlash adjustment of hypoid gear and pre-load adjustment of roller bearing
NOTE: Support drive pinion assembly with ST.
ST 498427100 STOPPER
5. Inspect and adjust backlash and tooth contact of hypoid gear.
6. 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:
T: 25 Nm (2.5 kgf-m, 18.1 ft. lbs.)
7. Selecting of main shaft rear plate
Using ST, 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.
ST 498147000 DEPTH GAUGE
8. Install clutch release lever and bearing.
9. Install transfer case and extension case assembly.
10. Install back-up light switch and neutral position switch.
11. Install the manual transmission assembly into the vehicle.
C: INSPECTION
1. Check the transmission case for cracks, damage, and oil leaks.
2. At neutral position, make sure that the gear shift is not leaning towards first, second, or back gear. If it is leaning, replace the shim and/or reverse accent shaft.
D: ADJUSTMENT
1. Make adjustment so that the heavy stroke (reverse side) is a little more than the light stroke (1st-2nd side).
2. To adjust, remove bolts holding reverse check sleeve assembly to the case, move sleeve assembly outward, and place adjustment shim (0 to 1 ea.) between sleeve assembly and case to adjust the clearance.
CAUTION: Be careful not to break O-ring when placing shim(s).
NOTE:
^ When shim is removed, the neutral position will move closer to reverse; when shim is added, the neutral position will move closer to 1st gear.
^ If shims alone cannot adjust the clearance, replace reverse accent shaft and re-adjust.