8. Main Shaft Assembly
REMOVAL1. Remove the manual transmission assembly from vehicle.
2. Remove the transfer case with extension case assembly.
3. Remove the transmission case.
4. Remove the drive pinion shaft assembly.
5. Remove the main shaft assembly.
INSTALLATION
1. Install the needle bearing and oil seal onto the front of transmission main shaft assembly.
NOTE:
^ Wrap the clutch splined section with vinyl tape to prevent damage to oil seal.
^ Apply grease (Unilube #2 or equivalent) to the sealing lip of oil seal.
^ Use a new one.
2. Install the needle bearing outer race knock pin hole into transmission case knock pin.
NOTE: Align the end face of seal with surface (A) when installing oil seal.
3. Install the drive pinion assembly.
4. Install the transmission case.
5. Install the transfer case with extension case assembly.
6. Install the manual transmission assembly to vehicle.
DISASSEMBLY
1. Put vinyl tape around the main shaft splines to protect oil seal from damage. Then pull out the oil seal and needle bearing by hand.
2. Remove the lock nut from transmission main shaft assembly.
NOTE: Remove the caulking before removing lock nut.
ST1 498937000 TRANSMISSION HOLDER
ST2 499987003 SOCKET WRENCH (35)
3. Remove the 5th-Rev sleeve and hub assembly, baulk ring, 5th drive gear and needle bearing.
4. Remove the snap ring and synchro cone stopper from 5th-Rev sleeve and hub assembly.
5. Using the ST1, ST2 and a press, remove the ball bearing, synchro cone and baulk ring (Rev).
NOTE:
^ Replace the sleeve and hub with new ones. Do not attempt to disassemble because they must engage at a specified point. If they should be disassembled, mark engagement point on splines beforehand.
^ Do not reuse the ball bearing.
ST1 499757002 INSTALLER
ST2 498077400 SYNCHRO CONE REMOVER
6. Using the ST1 and ST2, remove rest of the parts.
NOTE: Replace the sleeve and hub with new ones. Do not attempt to disassemble because they must engage at a specified point. If they should be disassembled, mark engagement point on splines beforehand.
ST1 899864100 REMOVER
ST2 899714110 REMOVER
ASSEMBLY
1. Assemble each sleeve and hub assembly.
NOTE: Position the open ends of spring 120° apart.
2. Install the 3rd drive gear, outer baulk ring, synchro cone, inner baulk ring, sleeve and hub assembly for 3rd needle bearing on transmission main shaft.
NOTE: Align the groove in baulk ring with shifting insert.
3. Install the 4th needle bearing race onto transmission main shaft using ST1, ST2 and a press.
NOTE: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
ST1 899714110 REMOVER
ST2 499877000 RACE 4-5 INSTALLER
4. Install the baulk ring, needle bearing, 4th drive gear and 4th gear thrust washer to transmission main shaft.
NOTE: Align the baulk ring and gear & hub assembly with key groove.
5. Drive the ball bearing onto the rear section of transmission main shaft using ST1, ST2 and a press.
NOTE: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
ST1 899714110 REMOVER
ST2 499877000 RACE 4-5 INSTALLER
6. Using the ST1 and ST2, install the 5th gear thrust washer and 5th needle bearing race onto the rear section of transmission main shaft.
NOTE:
^ Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
^ Face the thrust washer in correct direction.
ST1 899714110 REMOVER
ST2 499877000 RACE 4-5 INSTALLER
7. Install the bearing onto synchro cone.
8. Install the baulk ring and synchro cone onto 5th-Rev sleeve and hub assembly using ST and a press.
NOTE:
^ Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
^ Use a new ball bearing.
^ After press fitting, make sure the synchro cone rotates freely.
ST 499757002 INSTALLER
9. Install the synchro cone stopper and snap ring to 5th-Rev sleeve and hub assembly.
10. Install the rest parts to the rear section of transmission main shaft.
NOTE: Align the groove in baulk ring with shifting insert.
11. Tighten the lock nuts to the specified torque using ST1 and ST2.
NOTE: Secure the lock nuts in two places after tightening.
ST1 499987003 SOCKET WRENCH
ST2 498937000 TRANSMISSION HOLDER
Tightening torque: 120 Nm (12.2 kgf-cm, 88.5 ft. lbs.)
INSPECTION
Disassembled parts should be washed clean first and then inspected carefully.
1. Bearings Replace the bearings in the following cases:
^ Bearings whose balls, outer races and inner races are broken or rusty.
^ Worn bearings
^ Bearings that fail to turn smoothly or make abnormal noise when turned after gear oil lubrication.
^ Bearings having other defects
2. Bushing (each gear)
Replace the bushing in the following cases:
^ When the sliding surface is damaged or abnormally worn.
^ When the inner wall is abnormally worn.
3. Gears
^ Replace the gears with new ones if their tooth surfaces are broken, damaged, or excessively worn.
^ Correct or replace if the cone that contacts the baulk ring is rough or damaged.
^ Correct or replace if the inner surface or end face is damaged.
4. Baulk ring
Replace the ring in the following cases:
^ When the inner surface and end face are damaged.
^ When the ring inner surface is abnormally or partially worn down.
^ When the contact surface of the synchronizer ring insert is scored or abnormally worn down.
5. Shifting insert key
Replace the insert if deformed, excessively worn, or defective in any way.
6. Oil seal
Replace the oil seal if the lip is deformed, hardened, damaged, worn, or defective in any way.
7. O-ring
Replace the O-ring if the sealing face is deformed, hardened, damaged, worn, or defective in any way.
8. Gearshift mechanism
Repair or replace the gearshift mechanism if excessively worn, bent, or defective in any way.
ADJUSTMENT
Selection of main shaft rear plate:
Using the 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