Drive Pinion Shaft Assembly
Drive Pinion Shaft AssemblyREMOVAL
1. Remove the transmission assembly from vehicle.
2. Pull out the torque converter assembly.
3. Remove the input shaft.
4. Lift-up the lever on rear side of transmission harness connector, and then disconnect it from the stay.
5. Disconnect the inhibitor switch connector from the stay.
6. Disconnect the air breather hose.
7. Remove the oil charge pipe.
8. Remove the oil cooler inlet and outlet pipes.
9. Separate the converter case and transmission case part.
10. Separate the transmission case and extension case part.
11. Remove the reduction drive gear.
12. Remove the reduction driven gear.
13. Remove the drive pinion shaft mounting bolt and remove the drive shaft assembly from oil pump housing.
INSTALLATION
1. Assemble the drive pinion assembly to oil pump housing.
NOTE:
^ Be careful not to bend the shim.
^ Be careful not to press-fit the pinion into housing bore.
Tightening torque: 40 Nm (4.0 kgf-cm, 30 ft. lbs.)
2. Combine the torque converter case with transmission case.
3. Install the reduction driven gear.
4. Install the reduction drive gear.
5. Combine the transmission case with the extension case, and then install the rear vehicle speed sensor.
6. Insert the inhibitor switch and transmission connector to the stay.
7. Install the oil cooler inlet and outlet pipes.
8. Install the oil charge pipe with O-ring.
9. Insert the input shaft with rotating it by hand lightly, and then check the protrusion amount.
Normal protrusion A: 50 - 55 mm (1.97 - 2.17 inch)
10. Install the torque converter assembly.
11. Install the transmission assembly into vehicle.
DISASSEMBLY
1. Remove the caulking part of lock nut, and then remove the lock nut with holding the rear spline part of shaft using ST1 and ST2. Pull out the drive pinion collar.
ST1 498937110 HOLDER
ST2 499787700 WRENCH
ST3 499787500 ADAPTER
2. Remove the O-ring.
3. Separate the roller bearing and outer race from shaft using press.
4. Separate the front roller bearing from shaft using a press end ST.
ST 498517000 REPLACER
ASSEMBLY
1. Measure the dimension A of drive pinion shaft.
ST 398643600 GAUGE
2. Using a press, press-fit the new roller bearing into specified position.
NOTE: If excessive force is applied to roller bearing, the roller bearing will not turn easily.
3. After applying ATF, to a new O-ring and fitting it to the shaft, attach the drive pinion collar to shaft.
4. Install the lock washer to drive pinion shaft in proper direction.
5. Tighten the new lock nuts using ST1, ST2 and ST3.
Calculate the lock washer and lock nut specifications using following formula.
T2 = L2/(L1 + L2) x T1
T1: 116 Nm (11.8 kgf-cm, 85.3 ft. lbs.)
[Required torque setting]
T2: Tightening torque
L1: ST2 length 0.072 m (2.83 inch)
L2: Torque wrench length Example:
ST1 498937110 HOLDER
ST2 499787700 WRENCH
ST3 499787500 ADAPTER
NOTE: Install the ST2 to torque wrench as straight as possible.
6. Measure the starting torque of bearing. Make sure the starting torque is within the specified range. If the torque is not within specified range, replace the roller bearing.
Starting torque: 7.6 - 38.1 N (0.776 - 3.88 kgs, 1.7 - 8.6 lbs.)
7. Stake the lock nut at two points.
8. Measure the dimension B of drive pinion shaft.
ST 398643600 GAUGE
9. Calculate the thickness t (mm) of 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 cut, gouges, and other faults.
^ Adjust the teeth alignment.
ADJUSTMENT
1. Remove the liquid gasket completely.
2. Install the oil pump housing assembly to converter case, and secure them with tightening four bolts evenly.
NOTE: Use an old gasket or an aluminum washer so as not to damage the mating surface of housing.
Tightening torque: 41 Nm (4.2 kgf-cm, 30.4 ft. lbs.)
3. Rotate the drive pinion several times using ST1 and ST2.
ST1 498937110 HOLDER
ST2 499787700 WRENCH
4. Adjust backlash between drive pinion and crown gear.
5. Apply red lead evenly to the surfaces of three or four teeth on crown gear. Rotate the drive pinion in the forward and reverse directions for several times. Remove the oil pump housing, and check the tooth contact pattern.
If the tooth contact is improper, readjust the backlash or shim thickness.
^ Correct 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 pinion height adjusting washer in order to bring drive pinion close to driven gear.
^ Flank contact
Checking item: Backlash is too small. Contact pattern
Corrective action: Reduce thickness of pinion height adjusting washer in order to bring drive pinion away from driven near.
^ Toe contact (inside end contact)
Checking item: Contact area is small. Contact pattern
Corrective action: Reduce thickness of pinion height adjusting washer in order to bring drive pinion away from driven gear.
^ Heel contact (outside end contact)
Checking item: Contact area is small. Contact pattern
Corrective action: Increase thickness of pinion height adjusting washer in order to bring drive pinion close to driven 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. Tighten the lock plate with specified torque.
Tightening torque: 25 Nm (2.5 kgf-cm, 18 ft. lbs.)