Drive Pinion Shaft Assembly
Drive Pinion Shaft AssemblyREMOVAL
1. Remove the manual transmission assembly from the vehicle.
2. Remove the transfer case together with the extension case assembly.
3. Remove the transmission case.
4. Remove the drive pinion shaft assembly.
NOTE: Use a hammer handle, etc. to remove if too tight.
INSTALLATION
1. Remove the front differential assembly.
2. Alignment marks/numbers on hypoid gear set: The number (A) on top of the drive pinion, and the number on the hypoid driven gear are set numbers for the two gears. Use a pair having the same numbers.
The figure (B) below shows a number for shim adjustment. If no number is shown, the value is zero.
3. Place the drive pinion shaft assembly on transmission main case RH without shim and tighten the bearing mounting bolts.
4. Check and adjust the ST.
NOTE:
- Loosen the two bolts and adjust so that the scale indicates 0.5 correctly when the plate end and the scale end are on the same level.
- Tighten the two bolts.
ST 499917500 DRIVE PINION GAUGE ASSY
5. Position the ST by inserting the knock pin of ST into the knock hole of transmission case.
ST 499917500 DRIVE PINION GAUGE ASSY
6. Slide the drive pinion gauge scale with finger tip and read the value at the point where it matches with the end face of drive pinion.
ST 499917500 DRIVE PINION GAUGE ASSY
7. The thickness of shim shall be determined by adding the value indicated on drive pinion to the value indicated on the ST. (Add if the number on drive pinion is prefixed by +, and subtract if the number is prefixed by -.)
ST 499917500 DRIVE PINION GAUGE ASSY
8. Select one to three shims in the following table for the value determined as described above, and take the shim(s) which thickness is closest to the said value.
9. Install the front differential assembly.
10. Set the transmission main shaft assembly for single range and drive pinion shaft assembly in the install location. (When doing so, there will be no clearance between the two when moved all the way to the front). Inspect a suitable 1st-2nd, 3rd-4th and 5th shifter fork so that the coupling sleeve and reverse driven gear are positioned in the center of the synchronizing mechanism.
11. Install the transmission case.
12. Install the transfer case together with the extension case assembly.
13. Install the manual transmission assembly to the vehicle.
DISASSEMBLY
NOTE: Attach a cloth to the end of driven shaft (on the frictional side of the thrust needle bearing) to prevent damage during disassembly or reassembly.
1. Flatten the tab of the lock nut. Remove the lock nut with ST1, ST2 and ST3.
ST1 899884100 HOLDER
ST2 498427100 STOPPER
ST3 899988608 SOCKET WRENCH (27)
2. Draw out the drive pinion from driven shaft. Remove the differential bevel gear sleeve, adjusting washer No. 1, adjusting washer No. 2, thrust bearing, needle bearing and drive pinion collar.
3. Remove the roller bearing and washer using ST and a press.
NOTE: Do not reuse the roller bearing.
ST 498077000 REMOVER
4. Flatten the tab of the lock nut. Remove the lock nut using ST1 and ST2.
ST1 499987300 SOCKET WRENCH (50)
ST2 899884100 HOLDER
5. Remove the 5th driven gear using ST.
ST 499857000 5TH DRIVEN GEAR REMOVER
6. Remove the woodruff key.
7. Remove the roller bearing and 3rd-4th driven gear using ST1 and ST2.
ST1 499757002 INSTALLER
ST2 899714110 REMOVER
8. Remove the key.
9. Remove the 2nd driven gear, inner baulk ring, synchro cone and outer baulk ring.
10. Remove the 1st driven gear, inner baulk ring, synchro cone, outer baulk ring, 2nd gear bushing, gear and hub using ST1 and ST2.
NOTE: If necessary, use a new gear & hub assembly as a set, when replacing the gear or hub. Because these must engage at the specified point, avoid disassembly as much as possible. If it must be disassembled, mark the engaging point on the spline beforehand.
ST1 499757002 INSTALLER
ST2 899714110 REMOVER
11. Remove the sub gear, washer and snap ring (outer) of the 1st driven gear. (Non-turbo model)
ASSEMBLY
1. Install the sleeve and gear & hub assembly by matching alignment marks.
NOTE: After installation, make sure there is no significant gap at both sides of the ball detent.
NOTE: Use the new gear & hub assembly, if replacing the gear or hub.
2. Install the washer, snap ring (outer) and sub gear onto the 1st driven gear. (Non-turbo model)
3. Install the 1st driven gear, inner baulk ring, synchro cone and outer baulk ring, and gear & hub assembly onto driven shaft.
NOTE:
- Take care to install the gear & hub assembly in proper direction.
- Align the baulk ring and gear & hub assembly with the key groove.
4. Install the 2nd driven gear bushing onto driven shaft using ST1, ST2 and a press.
CAUTION: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
NOTE:
- Attach a cloth to the end of the driven shaft to prevent damage.
- When press fitting, align the oil holes of the shaft and bushing
ST1 499277200 INSTALLER
ST2 499587000 INSTALLER
5. Install the 2nd driven gear, inner baulk ring, synchro cone and outer baulk ring, and insert them onto driven shaft.
6. After installing key on driven shaft, install the 3rd-4th driven gear using an ST and a press.
CAUTION: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
NOTE: Align the groove in baulk ring with the insert.
ST 499277200 INSTALLER
7. Install a set of roller bearings onto the driven shaft using ST and a press.
CAUTION: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
ST 499277200 INSTALLER
8. Position the woodruff key in groove of the rear of driven shaft. Install the 5th driven gear onto driven shaft using ST and a press.
CAUTION: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
ST 499277200 INSTALLER
9. Install the lock washer. Tighten the lock nuts to the specified torque using ST1 and ST2.
ST1 499987300 SOCKET WRENCH (50)
ST2 899884100 HOLDER
Tightening torque: 260 N-m (26.5 kgf-m, 191.8 ft-lb)
NOTE:
- Crimp the locknut in 2 locations.
- Using a spring scale, check that starting torque of the roller bearing is 0.1 to 1.5 N (0.01 to 0.15 kgf, 0.02 to 0.34 lbf).
10. Install the roller bearing onto drive pinion.
NOTE: When installing the roller bearing, note its directions (front and rear) because the knock pin hole of outer race is offset.
11. Install the washer using ST1, ST2 and a press.
CAUTION: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
ST1 499277100 BUSHING 1-2 INSTALLER
ST2 499277200 INSTALLER
12. Install the thrust bearing and needle bearing. Install the driven shaft assembly.
13. Install the drive pinion collar, needle bearing, adjusting washer No. 2, thrust bearing, adjusting washer No. 1 and differential bevel gear sleeve in this order.
NOTE: Be careful to install the spacer in the proper direction.
14. Adjust the thrust bearing preload.
INSPECTION
Disassembled parts should be washed clean first with cleaning solvent and then inspected carefully.
1. Bearing
Replace the bearings in the following cases.
- When the bearing balls, outer races and inner races are broken or rusty.
- When the bearing is worn.
- When the bearings fail to turn smoothly or emit noise in rotation after gear oil lubrication.
- The ball bearing on the rear side of the drive pinion shaft should be checked for smooth rotation before the drive pinion assembly is disassembled. In this case, because a preload is working on the bearing, its rotation feels like it is slightly dragging unlike other bearings.
- When the bearing has other problems.
2. Bushing (each gear)
Replace the bushing in following cases.
- When the sliding surface is damaged or abnormally worn.
- When the inner wall is abnormally worn.
3. Gear
Replace the bearings in the following cases.
- Replace gear with new part if its tooth surfaces are broken, damaged or excessively worn.
- Correct or replace if the cone that contacts the baulk ring is rough or damaged.
- Corrector replace if the inner surface or end face is damaged.
4. Baulk ring
Replace the ring in following cases:
- When the inner surface and end face are damaged.
- When the ring inner surface is abnormally or partially worn down.
- If the gap between the end faces of the ring and the gear splined part is excessively small, check the clearance (A) while pressing the ring against the cone.
Clearance (A): 0. 5 mm (0.020 in) or more
- When the contact surface of the synchronizer ring insert section is scratched or abnormally worn.
5. Ball detent
Replace the ball detent if deformed, excessively worn or defective in any way.
6. Oil seal
Replace the oil seal if the lip is deformed, hardened, 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.
ADJUSTMENT
1. THRUST BEARING PRELOAD
1. Select a suitable adjusting washer No. 1 to so that dimension (H) will be zero in a visual check. Position the washer (18.3 x 30 x 4.and lock washer (18 x 30 x 2.and install lock nut. (18 x 13.5)
2. Using the ST1, ST2 and ST3, tighten the new lock nut to the specified torque.
ST1 899884100 HOLDER
ST2 498427100 STOPPER
ST3 899988608 SOCKET WRENCH (27)
Tightening torque: 120 N-m (12.2 kgf-m, 88.5 ft-lb)
3. After removing the ST2, measure the starting torque using torque driver.
ST1 899884100 HOLDER
ST3 899988608 SOCKET WRENCH (27)
Starting torque: 0.3 - 0.8 N-m (0.03 - 0.08 kgf-m, 0.2 - 0.6 ft-lb)
4. If the starting torque is not within the specified limit, select new adjusting washer No. 1 and recheck starting torque.
5. If the specified starting torque cannot be obtained by the selection of washer No. 1, select adjusting washer No. 2 from the list below. Repeat steps 1.through 4.to adjust starting torque.
6. Recheck that the starting torque is within the specified range, then crimp the lock nut at four positions.