Drive Pinion Shaft

Drive Pinion Shaft

REMOVAL
1. Remove the transmission assembly from vehicle.
2. Extract the torque converter clutch assembly.





3. Remove the input shaft.
4. Lift-up lever behind the transmission harness connector and disconnect it from stay.
5. Disconnect inhibitor switch connector from stay.
6. Disconnect the air breather hose.
7. Remove the oil charger pipe.
8. Remove the oil cooler inlet and outlet pipes.
9. Separation of torque converter clutch case and transmission case sections.
10. Separate transmission case and extension case sections.
11. Remove the reduction drive gear. (MPT model)
12. Remove the center differential carrier. (VTD model)
13. Remove the reduction driven gear.





14. Separation of drive pinion shaft and oil pump housing.

INSTALLATION
1. Assemble the drive pinion assembly to the oil pump housing.
2. Install oil pump housing to transmission case.
3. Combine the torque converter case with the transmission case.
4. Install the reduction driven gear.
5. Install the reduction drive gear. (MPT model)
6. Install the center differential carrier. (VTD model)
7. Combine the extension case with the transmission case, and install vehicle speed sensor 1 (rear).
8. Insert inhibitor switch and transmission connector into stay.
9. Install air breather hose.
10. Install the oil cooler inlet and outlet pipes.
11. Install the oil charger pipe with O-ring.





12. Insert the input shaft while turning lightly by hand. At this time, not to damage the bushing.
Normal protrusion A: 50 - 55 mm (1.97 - 2.17 inch)
13. Install the torque converter clutch assembly.
14. Install the transmission assembly to vehicle.

DISASSEMBLY





1. Straighten the staked portion of the lock nut, and remove the lock nut while locking the rear spline portion of the shaft with ST1 and ST2. Then pull off the drive pinion collar.
ST1 498937110 HOLDER
ST2 499787700 WRENCH
ST3 499787500 ADAPTER
2. Remove the O-ring.





3. Using a press, separate the rear roller bearing and outer race from the shaft.





4. Using a press and ST, separate the front roller bearing from the shaft.
ST 498517000 REPLACER

ASSEMBLY





1. Measure dimension "A" of the drive pinion shaft.
ST 398643600 GAUGE
2. Using a press, force-fit a new roller bearing in position.





NOTE: If too much pressure is applied, the roller bearing will not turn easily.

3. After fitting a new O-ring to the shaft, attach the drive pinion collar to the shaft.
4. Install the lock washer to drive pinion shaft in proper direction.
5. Tighten a new lock nut with ST1, ST2 and ST3. Calculate lock washer and lock nut specifications using the following formula.
T2 = L2/(L1 + L2 x T1
T1: 116 Nm (11.8 kgf-m, 85.3 ft. lbs.) [Required torque setting]
T2: Tightening torque
L1: ST2 length 0.072 mm (2.83 inch)
L2: Torque wrench length





Example:
ST1 498937110 HOLDER
ST2 499787700 WRENCH
ST3 499787500 ADAPTER





NOTE: Install ST2 to torque wrench as straight as possible.





6. Measure the starting torque of the bearing. Make sure the starting torque is within the specified range. If out of the allowable range, replace the roller bearing.
Starting torque: 7.6 - 38.1 N (0.776 - 3.88 kgf, 1.7 - 8.6 lb)








7. Stake the lock nut securely at two places.
8. Measure dimension "B" of the drive pinion shaft.
ST 398643600 GAUGE
9. The thickness "t" (mm) of the drive pinion shim.
t = 6.5±0.0625 - (B - A)
10. Select three or less shims from following table.

INSPECTION
^ Make sure that all component parts are free of harmful cuts, gouges, and other faults.
^ Adjust the teeth alignment.

ADJUSTMENT
1. Thoroughly remove the liquid gasket from the case mating surface beforehand.
2. Install the oil pump housing assembly to the torque converter clutch case, and secure evenly by tightening four bolts.





NOTE: Use an old gasket or an aluminum washer so as not to damage the mating surface of the housing.

Tightening torque: 41 Nm (4.2 kgf-m, 30.4 ft. lbs.)





3. Rotate the drive pinion several times with ST1 and ST2.
ST1 498937110 HOLDER
ST2 499787700 WRENCH
4. Adjust the backlash between drive pinion and crown gear.
5. Apply red lead evenly to the surfaces of three or four teeth of the crown gear. Rotate the drive pinion in the forward and reverse directions several times. Then remove the oil pump housing, and check the tooth contact pattern.
^ If tooth contact is improper, readjust the backlash or shim thickness.





^ Tooth contact
Checking item: Tooth contact pattern is slightly shifted toward to toe side under no-load rotation. [When loaded, contact pattern moves toward heel.]





^ Face contact
Checking item: Backlash is too large.
Contact pattern





Corrective action: Increase thickness of drive pinion height adjusting shim in order to bring drive pinion close to crown gear.





^ Flank contact
Checking item: Backlash is too small.
Contact pattern





Corrective action: Reduce thickness of drive pinion height adjusting shim in order to move drive pinion away from crown gear.





^ Toe contact (Inside end contact)
Checking item: Contact areas is small.
Contact pattern





Corrective action: Decrease thickness of drive pinion height adjusting shim in order to move drive pinion away from crown gear.





^ Heel contact (Outside end contact)
Checking item: Contact areas is small.
Contact pattern





Corrective action: Increase thickness of drive pinion height adjusting shim in order to move drive pinion close to crown gear.
6. If tooth contact is correct, mark the retainer position and loosen it. After fitting a new O-ring and oil seal, screw in the retainer to the marked position. Then tighten the lock plate to the specified torque.





Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft. lbs.)