Manual Transmission
DISASSEMBLYPart 1 Of 3:
Part 2 Of 3:
Part 3 Of 3:
Illustrated Index
Inspection
NOTE: To prevent damage to the transfer housing, always use soft jaws or equivalent materials between the transfer housing and the vise.
Transfer Gear (Hypoid Gear) Backlash Measurement
1. Set a dial indicator on the companion flange as shown.
2. Measure the transfer gear backlash.
STANDARD: 0.06 - 0.16 mm (0.002 - 0.006 inch)
Total Starting Torque Measurement
3. Rotate the companion flange several times to seat the tapered roller bearing.
4. Measure the starting torque (companion flange side) using a torque wrench.
STANDARD: 2.68 - 3.47 Nm (27.3 - 35.4 kgf.cm, 23.7 - 30.7 inch lbs.)
Transfer Gear (Hypoid Gear) Tooth Contact Inspection
5. Remove transfer cover B, then apply Prussian Blue to both sides of the transfer gear teeth lightly and evenly.
6. Rotate the companion flange in both directions until the transfer gear rotates one full turn in both directions.
7. Check the transfer gear tooth contact pattern.
8. If the measurements or the tooth contact pattern are not within the standard, disassemble the transfer assembly, replace worn or damaged parts, and reassemble it.
Disassembly
1. Remove the transfer covers A and B.
2. Cut the lock tabs of the locknut using a chisel. Keep all of the chiseled particles out of the transfer housing.
3. Hold the transfer shaft with a 14 mm Allen wrench clamped in a bench vise.
4. Loosen the transfer shaft locknut. The transfer shaft locknut has left-hand threads.
5. Remove the transfer shaft assembly, transfer drive gear, 25 mm thrust shim, transfer shaft collar, and tapered roller bearing from the transfer housing.
6. Secure the transfer housing in a bench vise with soft jaws.
7. Install the special tool on the companion flange, then loosen the transfer driven gear shaft locknut.
8. Remove the transfer driven gear shaft locknut, conical spring washer, back-up ring, O-ring, and companion flange.
9. Remove the transfer driven gear shaft, then remove the transfer spacer from the transfer driven gear shaft.
10. Remove the oil seal and the tapered roller bearing from the transfer housing.
Transfer Drive Gear Bearing Replacement
NOTE: Coat all parts with MTF during reassembly.
1. Remove the tapered roller bearing from the transfer drive gear using the special tools and a press.
2. Install the new tapered roller bearing in the transfer drive gear using the special tools and a press.
Transfer Driven Gear Shaft Bearing Replacement
NOTE: Coat all parts with MTF during reassembly.
1. Remove the tapered roller bearing from the transfer driven gear shaft using a press and a collar.
2. Install the 35 mm thrust shim on the transfer drive gearshaft.
3. Install the new tapered roller bearing on the transfer driven gear shaft using the special tools and a press.
NOTE: Use old transfer spacer for bearing installation, then discard it.
Transfer Shaft Disassembly/Reassembly
1. Support the transfer driven gear on steel blocks, then press the transfer shaft out of damper hub.
2. Align the damper hub grooves and transfer driven gear teeth, and reassemble the damper hub, needle bearing, and transfer driven gear.
3. Install the transfer shaft using a press.
Transfer Cover A Bearing Outer Race Replacement
NOTE: Coat all parts with MTF during reassembly.
1. Remove the tapered roller bearing outer race from transfer cover A by heating the cover to almost 212°F (100°C) using a heat gun. Do not heat the cover over 212°F (100°C).
2. Install the 68 mm thrust shim in transfer cover A.
3. Install the tapered roller bearing outer race using the special tools and a press.
Transfer Housing Bearing Outer Race Replacement
NOTE: Coat all parts with MTF during reassembly.
1. Remove the tapered roller bearing outer race from the transfer housing.
2. Install the new tapered roller bearing outer race using the special tools and a press.
Bearing Outer Race Locations And Special Tool Applications
REASSEMBLY
Note these items during reassembly:
^ While reassembling the transfer assembly:
- Check and adjust the transfer gear tooth contact.
- Measure and adjust the transfer gear backlash.-
- Check and adjust the tapered roller bearing starting torque.
^ Coat all parts with MTF during reassembly.
^ Replace the tapered roller bearing and the bearing outer race as a set if either part is replaced.
^ Replace the transfer drive gear and the transfer driven gear shaft as a set if either part is replaced.
Outline Of Assembly
1. Select the 35 mm thrust shim.
Perform this procedure if the transfer driven gear shaft or the tapered roller bearing on the transfer driven gear shaft is replaced.
2. Preassemble the parts to check and adjust transfer gear backlash and transfer gear tooth contact.
3. Disassemble the parts, then assemble the transfer driven gear shaft and its related parts.
4. Measure and adjust the starting torque of the transfer driven gear shaft tapered roller bearing.
5. Assemble the transfer shaft and its related parts.
6. Measure and adjust the total starting torque.
35 mm Thrust Shim Selection
1. Select the 35 mm thrust shim if the transfer driven gear shaft or the tapered roller bearing on the transfer driven gear shaft is replaced.
Calculate the thickness of the 35 mm thrust shim using the formula below.
FORMULA: A/100 - B/100 + C = X
A: Number on the existing transfer driven gear shaft
B: Number on the replacement transfer driven gear shaft
C: Thickness of the existing 35 mm thrust shim
X: Thickness needed for the replacement 35 mm thrust shim
NOTE: The number on the transfer driven gear shaft is shown in 1/100 mm.
X=A/100 - B/100 + C = 2/100 - (-1)/100 + 1.05 = 0.02 + 0.01 + 1.05 = 1.08mm
Select 35 mm thrust shim thickness of 1.08 mm (0.043 inch). If the tapered roller bearing on the transfer driven gear shaft is replaced.
Measure the thickness of the replacement bearing and the existing bearing, and calculate the difference of the bearing thickness. Adjust the thickness of the existing 35 mm thrust shim by the amount of difference in bearing thickness, and select the replacement 35 mm thrust shim. Do not use more than one 35 mm thrust shim to adjust the transfer gear backlash.
Transfer Gear Backlash Inspection And Transfer Gear Tooth Contact Inspection
2. Install the 35 mm thrust shim on the transfer driven gear shaft, then install the tapered roller bearing using the special tools and a press.
NOTE: Use old transfer spacer for bearing installation, then discard it.
3. Install the bearing outer race, then the tapered bearing on the companion flange side of the transfer housing.
4. Install the new oil seal on the transfer housing using the special tools.
5. Install the transfer driven gear shaft in the transfer housing. Do not install the transfer spacer on the transfer driven gear shaft in this step.
6. Install the companion flange, conical spring washer, and locknut on the transfer driven gear shaft. Do not install the O-ring and the back-up ring on the transfer gear shaft in this step.
7. Secure the transfer housing in a bench vise with soft jaws, then install the special tool on the companion flange. To prevent damage to the transfer housing, always use soft jaws or equivalent materials between the transfer housing and the vise.
8. Tighten the locknut while measuring the starting torque so the starting torque is within 0.98 - 1.39 Nm (10.0 - 14.2 kgf.cm, 8.68 - 12.3 inch lbs.).
NOTE:
^ Coat the threads of the locknut, and the shaft with MTF before installing the locknut.
^ Do not stake the locknut in this step.
STARTING TORQUE: 0.98 - 1.39 Nm (10.0 - 14.2 kgf.cm, 8.68 - 12.3 inch lbs.)
9. Install the transfer shaft assembly in the transfer housing, then install the tapered roller bearing, transfer shaft collar, 25 mm thrust shim, transfer drive gear, conical spring washer, and locknut on the transfer shaft.
NOTE:
^ Coat the threads of the locknut, and the shaft with IVITF before installing the locknut.
^ Do not stake the locknut in this step.
10. Hold the transfer shaft with a 14 mm Allen wrench clamped in a bench vise.
11. Tighten the transfer shaft locknut.
NOTE:
^ The transfer shaft locknut has left-hand threads.
^ Do not stake the locknut in this step.
TORQUE: 118 Nm (12.0 kgf.m, 86.8 ft. lbs.)
12. Temporarily install the transfer cover A without the 0-ring.
13. Rotate the companion flange several times to seat the tapered roller bearing.
14. Set a dial indicator on the companion flange, then measure the transfer gear backlash.
STANDARD: 0.06 - 0.16 mm (0.002 - 0.006 inch)
15. If the measurement is not within the standard, remove the transfer shaft locknut and replace the 25 mm thrust shim. Select and install a new 25 mm thrust shim, then recheck the measurement. Do not use more than one 25 mm thrust shim to adjust the transfer gear backlash.
16. Apply Prussian Blue to both sides of the transfer gear teeth lightly and evenly.
17. Rotate the companion flange in both directions until the transfer gear rotates one full turn in both directions.
18. Check the transfer gear tooth contact pattern.
19. If the transfer gear tooth contact is incorrect, adjust the transfer gear tooth contact with a 35 mm or 25 mm thrust shim.
NOTE:
^ To select a 35 mm thrust shim.
^ Do not use more than one 35 mm shim to adjust the transfer gear tooth contact.
^ To select the 25 mm thrust shim.
^ Do not use more than one 25 mm shim to adjust the transfer gear tooth contact.
- Toe Contact
Use a thicker 35 mm thrust shim to move the transfer driven gear shaft toward the transfer drive gear. Because this movement causes the transfer gear backlash to change, move the transfer drive gear away from the transfer driven gear shaft to adjust the transfer gear backlash as follows:
- Increase the thickness of the 25 mm thrust shim.
- Reduce the thickness of the 68 mm thrust shim by the amount of increased thickness of the 25 mm thrust shim.
- Heel Contact
Use a thinner 35 mm thrust shim to move the transfer driven gear shaft away from the transfer drive gear. Because this movement causes the transfer gear backlash to change, move the transfer drive gear toward the transfer driven gear shaft to adjust the transfer gear backlash as follows:
- Reduce the thickness of the 25 mm thrust shim.
- Increase the thickness of the 68 mm thrust shim by the amount of reduced thickness of the 25 mm thrust shim.
- Flank Contact
Use a thinner thrust shim to move the transfer drive gear toward the transfer driven gear shaft. Flank contact must be adjusted within the limits of the transfer gear backlash. If the backlash exceeds the limits, adjust as described under Heel Contact.
- Face Contact
Use a thicker thrust shim to move the transfer drive gear away from the transfer driven gear shaft. Face contact must be adjusted within the limits of the transfer gear backlash. If the backlash exceeds the limits, adjust as described under Toe Contact.
20. Remove the parts on the transfer shaft, and remove the transfer shaft from the transfer housing.
Transfer Driven Gear Shaft Starting Torque Inspection and Adjustment
21. Secure the transfer housing in a bench vise with soft jaws.
22. Install the special tool on the companion flange, then remove the transfer driven gear shaft locknut and the conical spring washer.
23. Remove the transfer driven gear shaft and the companion flange.
24. Install the new transfer spacer on the transfer driven gear shaft, then install them in the transfer housing.
25. Install the companion flange, O-ring, back-up ring, conical spring washer and locknut on the transfer driven gear shaft.
NOTE:
^ Coat the threads of the locknut, O-ring and transfer shaft with MTF before installing the locknut.
^ Install the conical spring washer in the direction shown.
26. Secure the transfer housing in a bench vise with soft jaws.
27. Install the special tool on the companion flange, then tighten the transfer driven gear shaft locknut while measuring the starting torque of the transfer driven gear shaft.
STARTING TORQUE: 0.98 - 1.39 Nm (10.0 - 14.2 kgf.cm, 8.68 - 12.3 inch lbs.)
TIGHTENING TORQUE: 132 - 216 Nm (13.5 - 22.0 kgf.m, 97.6 - 159 ft. lbs.)
NOTE:
^ Rotate the companion flange several times to seat the tapered roller bearing, then measure the starting torque.
^ If the starting torque exceeds 1.39 Nm (14.2 kgf.cm, 12.3 inch lbs.), replace the transfer spacer and reassemble the parts. Do not adjust the torque with the locknut loose.
^ If the tightening torque exceeds 216 Nm (22.0 kgf.m, 159 ft. lbs.), replace the transfer spacer and reassemble the parts.
^ Write down the measurement of the starting torque: it is used to measure the total starting torque.
28. Stake the locknut into the transfer driven gear shaft using a 3.5 mm punch.
29. Install the transfer shaft assembly in the transfer housing, then install the tapered roller bearing, transfer shaft collar, 25 mm thrust shim, transfer drive gear, conical spring washer, and transfer shaft locknut on the transfer shaft.
NOTE:
^ Coat the threads of the locknut and transfer shaft with MTF before installing the locknut.
^ Install the conical spring washer in the direction shown.
30. Hold the transfer shaft with a 14 mm Allen wrench clamped in a bench vise.
NOTE: The locknut has left-hand threads.
TORQUE: 118 Nm (12.0 kgf.m, 86.8 ft. lbs.)
31. Stake the locknut on the transfer shaft using a 3.5 mm punch.
Total Starting Torque Inspection And Adjustment
32. Temporarily install transfer cover A without the 0-ring.
33. Secure the transfer housing in a bench vise with soft jaws, then rotate the companion flange several times to fit the tapered roller bearing.
34. Measure the total starting torque.
TOTAL STARTING TORQUE: 1.70 - 2.08 Nm (17.3 - 21.2 kgf.cm, 15.0 - 18.4 inch lbs.) + Transfer Driven Gear Shaft Starting Torque Value (wrote down in step 27).
35. Remove transfer cover A.
36. If the measurement is out of specification, remove the 68 mm thrust shim from transfer cover A by heating the cover to almost 212°F (100°C) using a heat gun. Do not heat the cover higher than 212°F (100°C). Let the cover cool to room temperature before adjusting the starting torque.
If the measurement is within the specification, go to step 40.
37. Select the 68 mm thrust shim.
38. Install the 68 mm thrust shim using the special tools.
39. After replacing the 68 mm thrust shim, recheck and make sure the total starting torque is within the specification.
40. Coat the new O-rings with MTF, install them on transfer covers A and B, then install the covers on the transfer housing.