Drive Pinion Shaft Assembly
REMOVAL1. Remove the manual transmission assembly from vehicle.
2. Prepare the transmission for overhaul.
3. Remove the oil pipe, neutral position switch, back-up light switch and harness.
4. Remove the extension case.
5. Remove the transfer driven gear.
6. Remove the center differential.
7. Remove the oil pump.
8. Remove the transmission case.
9. Remove each gear assembly.
10. Remove the drive pinion shaft assembly.
INSTALLATION
1. Completely remove the remaining gasket on drive plate and clutch housing.
2. Apply liquid gasket to the clutch housing.
Liquid gasket: THREE BOND 1215 (Part No. 004403007)
3. Install each gear assembly.
4. Install the transmission case.
5. Install the oil pump.
6. Install the center differential.
7. Install the transfer driven gear.
8. Install the extension case.
9. Install the oil pipe, neutral position switch, backup light switch and harness.
10. Install the manual transmission assembly to vehicle.
DISASSEMBLY
NOTE: Replace the drive pinion shaft as a set with hypoid driven gear.
1. Remove the pipe and oil chamber.
2. Remove the drive pinion shaft and shim from adapter plate.
3. Secure the ST on workbench.
ST 18664AA000 BASE
4. Lift the caulking of lock nut.
5. Install the ST3 to lock nut, then set drive pinion shaft to ST. Remove the lock nut and washer.
ST1 18667AA000 HOLDER
ST2 18664AA000 BASE
ST3 18621AA000 ADAPTER WRENCH
6. Using the ST, remove the taper roller bearing assembly.
ST 18723AA000 REMOVER
ASSEMBLY
1. Using the ST, measure dimension A of drive pinion.
NOTE: Note dimension A for selection of drive pinion shim.
ST 398643600 GAUGE
2. Install the inner bearing inner race to drive pinion shaft using ST and press.
ST 18723AA000 REMOVER
CAUTION: Do not apply pressure in excess of 40 kN (4.0 ton, 4.4 US ton, 3.9 Imp ton).
3. Install the retainer and outer bearing inner race to drive pinion shaft using ST and press.
ST 18723AA000 REMOVER
NOTE: Press to the point where bearing is turned smoothly without slack.
4. Install the washer and a new lock nut.
5. Set the ST to drive pinion, then tighten the lock nut.
ST1 18667AA000 HOLDER
ST2 18664AA000 BASE
ST3 18621AA000 ADAPTER WRENCH
ST4 18852AA000 TORQUE WRENCH
NOTE: Tighten with the ST and torque wrench straight-lined.
Tightening torque: 265 Nm (27.0 kgf-cm, 195 ft. lbs.)
NOTE:
^ If torque wrench except ST4 is used, calculate the following equation, then tighten the lock nut. Tighten with the ST and torque wrench straight-lined. T=L1 /(0.1 + L1) x 285
6. Measure the starting torque.
7. Using the ST, caulk two portions on the lock nut to obtain dimension A 37 ± 0.5 mm (1.46 ± 0.02 inch).
ST 18670AA000 PUNCH
NOTE: Do not crack the caulking part of lock nut.
8. Using the ST, measure dimension B of the drive pinion.
ST 398643600 GAUGE
9. Calculate the following formula, then select one or two pieces of drive pinion shim from the table.
6.5 ± 0.0625 mm - (B - A) [0.26 ± 0.0025 inch - (B - A)]
NOTE:
A: Measured value from step 1.
B: Measured value from step 8.
10. Apply gear oil to the side face of taper roller bearing, then install the drive pinion shaft and selected shim to adapter plate.
Tightening torque: 54 Nm (5.5 kgf-cm, 40 ft. lbs.)
11. Install the oil chamber and pipe.
Tightening torque: 6.4 Nm (0.65 kgf-cm, 4.7 ft. lbs.)
INSPECTION
1. Using the spring balancer, measure the starting torque. If the starting torque is out of specification, replace the taper roller bearing.
Starting torque: 0 - 0.95 N (0 - 0.097 kgf, 0 - 0.21 lbs.)
2. Gears
Replace the gears in the following case.
^ Gear teeth surfaces are broken or excessively worn.
3. Bearings Replace the bearings in the following cases.
^ Worn, rusted and damaged bearing
^ Bearings that fail to turn smoothly or make abnormal noise when turned
4. Adapter plate
Replace the adapter plate in the following cases.
^ Worn, rusted and damaged bearing
^ Damaged adapter plate
5. Make sure the pipe and pipe chamber is not damaged or clogged. Repair or replace if damaged or clogged.
ADJUSTMENT
1. Inspect and adjust the backlash between hypoid driven gear and drive pinion.
2. Apply a uniform thin coat of red lead on both teeth surfaces of three or four teeth of the hypoid driven gear.
3. Install the drive pinion shaft assembly to clutch housing, then tighten it with at least four bolts.
NOTE: Install it with the remaining liquid gasket to prevent the mating surface of clutch housing and adapter plate from damaging.
Tightening torque: 50 Nm (5.1 kgf-cm, 36.9 ft. lbs.)
4. Using the ST, rotate several times.
ST 18631AA000 HANDLE
5. Remove the drive pinion shaft assembly, and then check tooth contact. If it is inaccurate, adjust the backlash or thickness of shim.
^ 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: Verify the backlash again, and then adjust it.
^ Flank contact
Checking item: Backlash is too small. Contact pattern
Corrective action: Verify the backlash again, and then adjust it.
^ Toe contact (Inside end contact)
Checking item: Contact areas is small. Contact pattern
Corrective action: Reduce thickness of drive pinion 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 shim in order to bring drive pinion close to crown gear.