Disassembly and Assembly
DISASSEMBLYCAUTION: Attach a cloth to the end of driven shaft (on the frictional side of thrust needle bearing) during disassembly or reassembly to prevent damage.
1. Straighten lock nut at staked portion. Remove the lock nut using ST1, ST2 and ST3.
ST1 899884100 HOLDER
ST2 498427100 STOPPER
ST3 899988608 SOCKET WRENCH
2. Withdraw drive pinion from driven shaft.
Remove differential bevel gear sleeve, adjusting washer No. 1, adjusting washer No. 2, thrust bearing, needle bearing, drive pinion collar, needle bearing and thrust bearing.
3. Remove roller bearing and washer using ST and press.
NOTE: Do not reuse roller bearing.
ST 498077000 REMOVER
4. Straighten lock nut at staked portion. Remove the lock nut using ST1 and ST2.
ST1 499987300 SOCKET WRENCH (50)
ST2 899884100 HOLDER
5. Remove 5th driven gear using ST.
ST 499857000 5TH DRIVEN GEAR REMOVER
6. Remove woodruff key.
7. Remove roller bearing, 3rd-4th driven gear using ST1 and ST2.
ST1 499757002 INSTALLER
ST2 899714110 REMOVER
8. Remove the key.
9. Remove 2nd driven gear, inner baulk ring, synchro cone and outer baulk ring.
10. Remove 1st driven gear, 2nd gear bushing, gear and hub using ST1 and ST2.
NOTE: Replace gear and hub if necessary. Do not attempt to disassemble if at all possible because they must engage at a specified point. If they have to be disassembled, mark the engaging point beforehand.
ST1 49975002 INSTALLER
ST2 899714110 REMOVER
11. Remove sub gear for 1st driven gear.
ASSEMBLY
1. Install sleeve and assembly by matching alignment marks.
NOTE:
^ Use new gear and hub assembly, if gear or hub have been replaced.
2. Install washer, snap ring and sub gear to 1st driven gear.
3. Install 1st driven gear, 1st baulk ring, gear and hub assembly onto driven shaft.
NOTE:
^ Take care to install gear and hub assembly in proper direction.
^ Align baulk ring and gear & hub assembly with key groove.
4. Install 2nd driven gear bushing onto driven shaft using ST1, ST2 and 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 driven shaft to prevent damage.
^ When press fitting, align oil holes of shaft and bushing.
ST1 499277200 INSTALLER
ST2 499587000 INSTALLER
5. Install 2nd driven gear, inner baulk ring, synchro cone, outer baulk ring and insert onto driven shaft.
6. After installing key on driven shaft, install 3rd 4th driven gear using ST and press.
CAUTION: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
NOTE: Align groove in baulk ring with insert.
ST 499277200 INSTALLER
7. Install a set of roller bearings onto the driven shaft using ST and 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 woodruff key in groove on the rear of driven shaft. install 5th driven gear onto drive shaft using ST and press.
CAUTION: Do not apply/pressure in excess of 10 kN (1 ton, 1.1 US ton ,10 Imp ton).
ST 499277200 INSTALLER
9. Install lock washer. Install lock nut and tighten to the specified torque using ST. ST 499987300 SOCKET WRENCH (50)
Tightening torque: 265 Nm (27 kgf-cm, 195 ft. lbs.)
NOTE:
^ Stake lock nut at two points.
^ Using spring balancer, check that starting torque of roller bearing is 0.1 to 1.5 N (0.01 to 0.15 kgf, 0.02 to 0.33 lbs.).
10. Install roller bearing onto drive pinion.
NOTE: When installing roller bearing, note its directions (front and rear) because knock pin hole in outer race is offset.
11. Install washer using ST1, ST2 and 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 thrust bearing and needle bearing. Install driven shaft assembly.
13. Install drive pinion collar, needle bearing, adjusting washer No. 2, thrust bearing, adjusting washer No. 1 and differential bevel gear sleeve in that order.
NOTE: Be careful to install spacer in proper direction.