Combination of Transmission Case
2. COMBINATION OF TRANSMISSION CASE
1) Alignment marks/numbers on hypoid gear set (1) The upper number on driven pinion is the match number for combining it with hypoid driven gear. The lower number is for shim adjustment. If no lower number is shown, the value is zero. The number on hypoid driven gear indicates a number for combination with drive pinion.
2) Adjustment of drive pinion shim (2)
(1) Place drive pinion shaft assembly on right hand transmission main case without shim and tighten bearing mounting bolts.
(2) Inspection and adjustment of 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
(3) Position the ST by inserting the knock pin of ST into the knock hole in the transmission case.
(4) 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.
(C): Adjust clearance to zero without shim.
(5) 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
Select one to three shims from the next table for the value determined as described above and take a shim thickness which is closest to the said value.
3) Install differential assembly (3) on left hand transmission case.
CAUTION: Be careful not to fold the sealing lip of oil seal.
NOTE: Wrap the left and right splined sections of axle shaft with vinyl tape to prevent scratches.
4) Install needle bearing and oil seal onto the front of transmission main shaft assembly (4), and position in left side transmission case.
CAUTION:
- Wrap 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.
NOTE:
- Align the end face of seal with surface A of left side transmission main case when installing oil seal.
- Be careful not to drop oil seal when installing right side transmission main case.
- Make sure straight pin is positioned in hole in needle bearing's outer race.
5) Install drive pinion shaft assembly (5) with shims selected before into transmission case.
NOTE: Ensure that the knock pin of the case is fitted into the hole in the bearing outer race.
6) Selection of suitable 1st-2nd, 3rd-4th and 5th shifter fork
Set transmission main shaft assembly and drive pinion shaft assembly in position (so there is no clearance between the two when moved all the way to the front). Select suitable 1st-2nd, 3rd-4th and 5th shifter fork so that coupling sleeve and reverse driven gear are positioned in the center of their synchronizing mechanisms.
7) Inspection of rod end clearance
Measure rod end clearances A and B. If any clearance is not within specifications, replace rod or fork as required.
8) Combination of transmission case
(1) Wipe off grease, oil and dust on the mating surfaces of transmission cases with white gasoline, and apply liquid gasket, and then put case right side and left side together.
Liquid gasket:
THREE BOND 1215 or equivalent
(2) Tighten 17 bolts with bracket, clip, etc. as shown in the figure.
Tightening torque:
8 mm bolt
25 ± 2 Nm (2.5 ± 0.2 kg-m, 18.1 ± 1.4 ft-lb)
* 10 mm bolt
39 ± 3 Nm (4.0 ± 0.3 kg-m, 28.9 ± 2.2 ft-lb)
NOTE:
- Insert bolts from the bottom and tighten nuts at the top.
- Put cases together so that drive pinion shim and input shaft holder shim are not caught up in between.
- Confirm that counter gear and speedometer gear are meshed.
9) Tighten ball bearing attachment bolts.
Tightening torque:
29 ± 3 Nm (3.0 ± 0.3 kg-m, 21.7 ± 2.2 ft-lb)
10) Backlash adjustment of hypoid gear and preload adjustment of roller bearing.
NOTE: Support drive pinion assembly with ST. ST 498427100 STOPPER
(1) Place the transmission with case left side facing downward and put ST1 on bearing cup.
(2) Screw retainer assembly into left case from the bottom with ST2. Fit ST3 on the transmission main shaft. Shift gear into 4th or 5th and turn the shaft several times. Screw in the retainer while turning ST3 until a slight resistance is felt on ST2.
This is the contact point of hypoid gear and drive pinion shaft. Repeat the above sequence several times to ensure the contact point.
ST1 399780104 WEIGHT
ST2 499787000 WRENCH ASSY
ST3 499927100 HANDLE
(3) Remove weight and screw in retainer without 0-ring on the upper side and stop at the point where slight resistance is felt.
NOTE: At this point, the backlash between the hypoid gear and drive pinion shaft is zero. ST 499787000 WRENCH ASSY
(4) Fit lock plate (11) . Loosen the retainer on the lower side by 1-1/2 notches of lock plate and turn in the retainer on the upper side by the same amount in order to obtain the backlash.
NOTE: The notch on the lock plate moves by 1/2 notch if the plate is turned upside down.
(5) Turn in the retainer on the upper side additionally by 1 notch in order to apply preload on taper roller bearing.
(6) Tighten temporarily both the upper and lower lock plates and mark both holder and lock plate for later readjustment.
(7) Turn transmission main shaft several times while tapping around retainer lightly with plastic hammer.
(8) Set ST1 and ST2. Insert the needle through transmission oil drain plug hole so that the needle comes in contact with the tooth surface at a right angle and check the backlash.
ST1 498247001 MAGNET BASE
ST2 498247100 DIAL GAUGE
Backlash:
0.13 -0.18 mm (0.0051 - 0.0071 in)
NOTE;
- If backlash is outside specified range, adjust it by turning holder in right side case.
- Turning holder pawl 1/2 rotation changes backlash by approximately 0.04 mm (0.0016 in).
(9) Check tooth contact of hypoid gear as follows; Apply a uniform thin coat of red lead on both tooth surfaces of 3 or 4 teeth of the hypoid gear. Move the hypoid gear back and forth by turning the transmission main shaft until a definite contact pattern is developed on hypoid gear, and judge whether face contact is correct. It it is incorrect, make the following correction.
- Tooth contact is correct.
- Backlash is excessive.
To reduce backlash, loosen holder on the upper side (case right side) and turn in the holder on the lower side (case left side) by the same amount.
- Backlash is insufficient.
To increase backlash, loosen holder on the lower side (case left side) and turn in the holder on the upper side (case right side) by the same amount.
- The drive pinion shim selected before is too thick. Reduce its thickness.
- The drive pinion shim selected before is too thin. Increase its thickness.
11) After checking the tooth contact of hypoid gears, remove the lock plate (11) . Then loosen retainer until the 0-ring groove appears. Fit 0-ring into the groove and tighten retainer into the position where retainer has been tightened in.
Tighten lock plate (11).
Tightening torque:
25 ± 3 Nm (2.5 ± 0.3 kg-m, 18.1 ± 2.2 ft-lb)
NOTE; Carry out this job on both upper and lower retainers.
12) Selecting of main shaft rear plate
Using ST, measure the amount A of ball bearing protrusion from transmission main case surface and select the proper plate in the following table: ST 498147000 DEPTH GAUGE
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.
13) Install clutch release lever (1) and bearing (2).