Drive Pinion Shaft Assembly
Drive Pinion Shaft AssemblyREMOVAL
1) Remove the transmission assembly from the vehicle.
2) Remove the air breather hose.
3) Remove the control valve body.
4) Remove the transmission harness.
5) Remove the turbine speed sensor.
6) Remove the secondary speed sensor.
7) Remove the primary speed sensor.
8) Remove the inhibitor switch.
9) Remove the extension case.
10) Remove the transfer clutch assembly.
11) Remove the transfer driven gear assembly.
12) Remove the parking pawl.
13) Remove the reduction driven gear assembly.
14) Remove the oil pan and oil strainer.
15) Remove the transmission control device.
16) Remove the transmission case.
17) Remove the reduction drive gear.
18) Remove the primary pulley, secondary pulley and variator chain.
19) Remove the reverse brake assembly.
20) Remove the forward clutch assembly.
21) Using the ST, remove the drive pinion retainer.
ST 18270KA020 SOCKET (E20)
22) Remove the O-ring.
INSTALLATION
1) Clean the mating surface of drive pinion retainer and converter case.
2) Adjust the backlash and tooth contact between drive pinion shaft assembly and the front differential side gear.
3) Install O-rings in two locations to the converter case.
NOTE:
^ Use new O-rings.
^ Apply CVTF to the O-ring.
4) Apply liquid gasket seamlessly to the mating surface of drive pinion retainer.
Liquid gasket:
THREE BOND 1215 (Part No. 004403007) or equivalent
5) Install the drive pinion retainer to converter case, and tighten the bolt using the ST.
ST 18270KA020 SOCKET (E20)
NOTE:
Do not confuse the three different-length bolts when installing.
Tightening torque:
43 Nm (4.4 kgf-m, 31.7 ft-lb)
6) Install the forward clutch assembly.
7) Install the reverse brake assembly.
8) Install the primary pulley, secondary pulley and variator chain.
9) Install the reduction drive gear.
10) Install the transmission case.
11) Install the transmission control device.
12) Install the oil strainer and oil pan.
13) Install the reduction driven gear assembly.
14) Install the transfer driven gear assembly.
15) Install the transfer clutch assembly.
16) Install the parking pawl.
17) Install the extension case.
18) Install the inhibitor switch.
19) Install the secondary speed sensor.
20) Install the primary speed sensor.
21) Install the turbine speed sensor.
22) Install the transmission harness.
23) Install the control valve body.
24) Install the air breather hose.
25) Install the transmission assembly to the vehicle.
DISASSEMBLY
1) Flatten the tab of the lock nut.
2) Using ST1, ST2 and ST3, fix at the spline portion of drive pinion shaft to remove the lock nut.
ST1 499787500 ADAPTER
ST2 499787700 WRENCH
ST3 498937110 HOLDER
3) Remove the drive pinion shaft from the drive pinion retainer.
4) Using the round bar with diameter of 36 mm (1.42 in) or 37 mm (1.46 in), remove the bearing inner race and plug.
5) Remove the drive pinion washer.
6) Remove the drive pinion spacer.
7) Remove the O-ring.
8) Remove the inner race and drive pinion shim from drive pinion shaft using ST.
ST 498515500 REMOVER
9) Using the ST, remove the outer race.
ST 398527700 PULLER ASSY
10) Remove the two oil seals using a screwdriver wrapped with cloth etc.
CAUTION:
Do not damage the fitting surface of oil seal.
11) Remove the plug from drive pinion retainer.
ASSEMBLY
1) Install the plug to drive pinion retainer.
NOTE:
^ Use new O-rings.
^ Apply CVTF to the O-ring.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
2) Using the ST, install the oil seal to drive pinion retainer.
NOTE:
^ Apply CVTF to the oil seal press-fitting surface and lip.
^ Install the oil seal in the correct direction.
ST 927720000 HOUSING BUSHING INSTALLER AND REMOVER
3) Select the drive pinion washer.
(1) Measure the roller bearing inner race width "A" on the front side.
(2) Measure the roller bearing inner race width "B" on the rear side.
(3) Measure the spacer width "C".
(4) Using the ST, install the front roller bearing outer race to the drive pinion retainer.
ST1 28499TC010 INSTALLER
ST2 398177700 INSTALLER
(5) Using the ST, install the rear roller bearing outer race to the drive pinion retainer.
ST 20099AE020 INSTALLER
(6) Place the drive pinion retainer on the surface plate, and install the inner race to the rear roller bearing outer race.
NOTE:
Place the drive pinion retainer so that the mating surface of the drive pinion retainer (mating surface with the converter case) contacts the surface plate.
(7) Measure the height "D" from the end face of the rear roller bearing inner race to the surface plate.
(8) Install the inner race to the front roller bearing outer race.
(9) Measure the depth "E" from the end face of the front roller bearing inner race to the end face of the ST.
ST 499575400 GAUGE
(10) Using following formula, select one to three drive pinion washers.
T (mm) = D - (A + B + C + E - 15) - (0±0.0125)
[T (in) = D - (A + B + C + E - 0.591) - (0±0.0005)]
A: Front roller bearing width
B: Rear roller bearing width
C: Spacer width
D; Height from end face of rear roller bearing inner race to surface plate
E: Depth from end face of front roller bearing inner race to end face of ST
15 mm (0.591 in): Thickness of ST
T: Drive pinion washer thickness
0±0.0125 mm (0±0.0005 in): Clearance
4) Measure and record the drive pinion shim thickness to be reused.
5) Install the drive pinion shim that is reused for the drive pinion shaft.
6) Using the ST1 and ST2, press-fit the inner race to the drive pinion shaft.
ST1 899580100 INSTALLER
ST2 927130000 EXTENSION DRIVE SHAFT
7) Install the drive pinion spacer.
NOTE:
Replace the O-ring with a new part after tooth contact inspection.
8) Install the selected drive pinion washer.
9) Insert the drive pinion shaft into the drive pinion retainer.
CAUTION:
Be careful not to damage the oil seal.
10) Install the inner bearing and lock nut.
NOTE:
Use a new lock nut.
11) Using the ST, tighten the lock nut to the specified torque so that the starting torque of the drive pinion shaft is within the specified range.
CAUTION:
Before inspecting the starting torque, apply differential gear oil to roller of bearing and rotate the bearing several times.
NOTE:
^ Tighten the lock nut while directly aligning ST2 and torque wrench.
^ If the starting torque is not within the specified range, select the drive pinion washer, and repeat the step until the starting torque is within the specified range.
^ When a thicker drive pinion washer is selected, the starting torque decreases. When a thinner drive pinion washer is selected, the starting torque increases.
Starting torque:
5.1 - 17.1 N (0.5 - 1.7 kgf, 1.1 - 3.8 lbf)
ST1 499787500 ADAPTER
ST2 499787700 WRENCH
ST3 498937110 HOLDER
Using the following formula, calculate the tightening torque for a torque wrench.
T2 = L2/(L1 + L2) � T1
T1: 170 - 250 Nm (17.3 - 25.5 kgf-m, 125.4 - 184.4 ft-lb) [Specified tightening torque range]
T2: Tightening torque
L1: ST1 length 0.072 m (2.83 in)
L2: Torque wrench length
Example:
12) Install the drive pinion retainer to the converter case, and check the backlash and tooth contact.
13) Remove the drive pinion retainer from converter case.
14) Remove the drive pinion spacer from the drive pinion shaft.
15) Install the O-ring to the drive pinion shaft.
NOTE:
^ Use new O-rings.
^ Apply CVTF to the O-ring.
16) Install the drive pinion spacer to the drive pinion shaft.
17) Install the drive pinion washer.
18) Insert the drive pinion shaft into the drive pinion retainer.
CAUTION:
Be careful not to damage the oil seal.
19) Install the inner bearing and lock nut.
20) Using the ST, tighten the lock nut to the specified torque so that the starting torque of the drive pinion shaft is within the specified range.
CAUTION:
Before inspecting the starting torque, apply differential gear oil to roller of bearing and rotate the bearing several times.
NOTE:
^ Tighten the lock nut while directly aligning ST2 and torque wrench.
^ If the starting torque is not within the specified range, select the drive pinion washer, and repeat the step until the starting torque is within the specified range.
^ When a thicker drive pinion washer is selected, the starting torque decreases. When a thinner drive pinion washer is selected, the starting torque increases.
Starting torque:
5.1 - 17.1 N (0.5 - 1.7 kgf, 1.1 - 3.8 lbf)
ST1 499787500 ADAPTER
ST2 499787700 WRENCH
ST3 498937110 HOLDER
Using the following formula, calculate the tightening torque for a torque wrench.
T2 = L2/(L1 + L2) � T1
T1: 170 - 250 Nm (17.3 - 25.5 kgf-m, 125.4 - 184.4 ft-lb) [Specified tightening torque range]
T2: Tightening torque
L1: ST1 length 0.072 m (2.83 in)
L2: Torque wrench length
Example:
21) Crimp the lock nut in 2 locations.
22) Using the ST, install the plug.
ST1 499755602 PRESS SNAP RING
ST2 398177700 INSTALLER
INSPECTION
^ Make sure that all component parts are free of scratches, holes and other faults.
^ Check the tooth contact.
^ Apply CVTF to bearing and rotate the bearing to check for noise or dragging etc.
^ Check the starting torque of drive pinion shaft.
CAUTION:
Before measuring, apply differential gear oil to roller of bearing and rotate the bearing several times.
ST1 498937110 HOLDER
ST2 499787700 WRENCH
Starting torque:
5.1 - 17.1 N (0.5 - 1.7 kgf, 1.1 - 3.8 lbf)
ADJUSTMENT
1) Remove the liquid gasket from the mating surface completely.
2) Using the ST, install the drive pinion retainer to converter case.
ST 18270KA020 SOCKET (E20)
NOTE:
Do not confuse the three different-length bolts when installing.
Tightening torque:
43 Nm (4.4 kgf-m, 31.7 ft-lb)
3) Rotate the drive pinion several times using ST1 and ST2.
ST1 498937110 HOLDER
ST2 499787700 WRENCH
4) Adjust the drive pinion and hypoid driven gear backlash.
5) Using the ST, remove the drive pinion retainer from converter case.
ST 18270KA020 SOCKET (E20)
6) Apply lead-free red dye evenly on the both sides of three to four teeth of the hypoid driven gear. Then install the drive pinion retainer and rotate the drive pinion in both directions several times. Remove the drive pinion retainer and check the tooth contact pattern.
If the teeth contact is inappropriate, adjust the backlash or thickness of the shim.
NOTE:
After correction, wipe off the lead-free red dye.
^ Correct tooth contact
Check item: Tooth contact surface is slightly shifted toward the toe side under a no-load condition. (When driving, it moves towards the heel side.)
^ Face contact
Check item: Backlash is too large.
Contact pattern
Corrective action: Increase thickness of drive pinion shim according to the procedures for moving the drive pinion close to hypoid driven gear.
^ Flank contact
Check item: Backlash is too small.
Contact pattern
Corrective action: Reduce the thickness of the drive pinion shim according to the procedures for moving the drive pinion away from the hypoid driven gear.
^ Toe contact (inside contact)
Check item: Teeth contact area is too small.
Contact pattern
Corrective action: Reduce the thickness of the drive pinion shim according to the procedures for moving the drive pinion away from the hypoid driven gear side.
^ Heel contact (outside end contact)
Check item: Teeth contact area is too small.
Contact pattern
Corrective action: Increase the thickness of the drive pinion shim according to the procedures for moving the drive pinion closer to the hypoid driven gear.
7) Using the ST, loosen the differential side retainer until the mounting groove of the O-ring appears, and then install the O-ring.
NOTE:
^ When loosening the differential side retainer, record the number of the turns made.
^ Perform this for both left and right differential side retainers.
^ Use new O-rings.
^ Apply the differential gear oil to O-ring.
ST 18658AA020 WRENCH COMPL RETAINER
8) Using the ST, tighten the retainer to the position before it is loosened.
ST 18658AA020 WRENCH COMPL RETAINER
9) Replace the differential side retainer oil seal with a new part.
10) Install the lock plate.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
