Main Shaft Assembly For Single-Range
Main Shaft Assembly for Single-RangeREMOVAL
1. Remove the manual transmission assembly from vehicle.
2. Remove the transfer case with extension case assembly.
3. Remove the transmission case.
4. Remove the drive pinion shaft assembly.
5. Remove the main shaft assembly for single range.
INSTALLATION
1. Install the needle bearing and oil seal onto the front of transmission main shaft assembly for single range.
NOTE:
- Wrap the 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.
- Use a new oil seal.
2. Install the transmission case knock pin into needle bearing outer race knock pin hole.
NOTE: Align the end face of seal with surface (A) when installing oil seal.
3. Install the drive pinion assembly.
4. Install the transmission case.
5. Install the transfer case with extension case assembly.
6. Install the manual transmission assembly into vehicle.
DISASSEMBLY
1. Put the vinyl tape around main shaft splines to protect oil seal from damage. Then pull out the oil seal and needle bearing by hand.
2. Remove the lock nut from transmission mainshaft assembly for single range.
NOTE: Unlock the caulking before removing lock nut.
ST1 498937000 TRANSMISSION HOLDER
ST2 499987003 SOCKET WRENCH (35)
3. Remove the 5th-Rev sleeve & hub assembly, baulk ring, 5th drive gear & needle bearing.
4. Remove the snap ring and synchro cone stopper from 5th-Rev sleeve & hub assembly.
5. Using the ST1, ST2 and a press, remove the ball bearing, synchro cone and baulk ring (Rev).
NOTE:
- When replacing the sleeve & hub with new ones, replace them as a set.
- Do not disassemble the sleeve & hub, because the aligning position is specified.
- If it is necessary to disassemble, mark the engaging points on the splines beforehand.
- Do not reuse the ball bearing.
ST1 499757002 INSTALLER
ST2 498077400 SYNCHRO CONE REMOVER
6. Using the ST1 and ST2, remove the rest of parts.
NOTE:
- When replacing the sleeve & hub with new ones, replace them as a set.
- Do not disassemble the sleeve & hub, because the aligning position is specified.
- If it is necessary to disassemble, mark the engaging points on the splines beforehand.
ST1 899864100 REMOVER
ST2 899714110 REMOVER
ASSEMBLY
1. When the sleeve & hub assemblies have been disassembled, reassemble with aligning each engaging point.
NOTE: Position open ends of spring 120° apart.
2. Install the 3rd drive gear, outer baulk ring, synchro cone, inner baulk ring, sleeve & hub assembly for 3rd needle bearing, on the transmission main shaft.
NOTE: Align the groove in baulk ring with shifting insert.
3. Install the 4th needle bearing race onto transmission main shaft using ST1, ST2 and a press.
NOTE: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
ST1 899714110 REMOVER
ST2 499877000 RACE 4-5 INSTALLER
4. Install the baulk ring, needle bearing, 4th drive gear and 4th gear thrust washer to transmission main shaft.
NOTE: Align the baulk ring and gear & hub assembly with key groove.
5. Press the ball bearing into the rear section of transmission main shaft using ST1, ST2 and a press.
NOTE: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
ST1 899714110 REMOVER
ST2 499877000 RACE 4-5 INSTALLER
6. Using the ST1 and ST2, install the 5th gear thrust washer and 5th needle bearing race onto the rear section of transmission main shaft.
NOTE:
- Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
- Face the thrust washer in the correct direction.
ST1 899714110 REMOVER
ST2 400877000 RACE 4-5 INSTALLER
7. Install the bearing onto synchro cone.
8. Install the baulk ring and synchro cone onto 5thRev sleeve & hub assembly using ST and a press.
NOTE:
- Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
- Use new ball bearing.
- Make sure the synchro cone rotates smoothly after press-fitting.
ST 499757002 INSTALLER
9. Install the synchro cone stopper and snap ring to 5th-Rev sleeve & hub assembly.
10. Install the rest of parts to the rear section of transmission main shaft.
NOTE: Align the groove in baulk ring with shifting insert.
11. Tighten the lock nuts to the specified torque using ST1 and ST2.
NOTE: Caulk the lock nuts in two places after tightening.
ST1 499987003 SOCKET WRENCH
ST2 498937000 TRANSMISSION HOLDER
Tightening torque: 120 Nm (12.2 kgf-cm, 88.5 ft. lbs.)
INSPECTION
Disassembled parts should be washed with unleaded gasoline first and then inspected carefully.
1. Bearings
Replace the bearing in 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.
- When bearings have other defects.
2. Bushing (each gear)
Replace the bushings in following cases:
- When the sliding surface is damaged or abnormally worn.
- When the inner wall is abnormally worn.
3. Gears
- Replace gears with new ones if their tooth surfaces are broken, damaged or excessively worn.
- Correct or replace if the cone that contacts the baulk ring is rough or damaged.
- Correct or 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 is damaged.
- When the ring inner surface is abnormally or partially worn.
- When contact surfaces of the synchronizer ring insert have cracks or abnormally worn.
5. Shifting insert key
Replace the insert key 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.
8. Gearshift mechanism
Repair or replace the gearshift mechanism if excessively worn, bent or defective in any way.
ADJUSTMENT
Selection of main shaft rear plate:
Using the ST, measure the amount (A) of ball bearing protrusion from transmission main case surface, and select a suitable plate in the following table.
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 moving flange of bearing.
ST 498147001 DEPTH GAUGE