3-1 [W3A1] SERVICE PROCEDURE

3. Drive Pinion Assembly

3. Drive Pinion Assembly 3) Remove roller bearing and washer (33 × 50 ×

5) using ST and press.
A: DISASSEMBLY CAUTION:
1. DRIVE PINION SHAFT Do not reuse roller bearing.
1) Straighten lock nut at staked portion. Remove ST 498077000 REMOVER
the lock nut using ST1, ST2 and ST3.
ST1 899884100 HOLDER
ST2 498427100 STOPPER
ST3 899988608 SOCKET WRENCH

G3M0607

2. DRIVEN GEAR ASSEMBLY

G3M0595
CAUTION:
Attach a cloth to the end of driven shaft (on the
2) Withdraw drive pinion from driven shaft. frictional side of thrust needle bearing) during
Remove differential bevel gear sleeve, adjusting disassembly or reassembly to prevent damage.
washer No. 1, adjusting washer No. 2, thrust 1) Straighten lock nut at staked portion. Remove
bearing, needle bearing, drive pinion collar, needle the lock nut using ST1 and ST2.
bearing and thrust bearing. ST1 499987300 SOCKET WRENCH (50)
ST2 899884100 HOLDER

B3M0536G

(A) Differential bevel gear sleeve G3M0608

(B) Washer No. 1 (25 × 37.5 × t)

2) Remove 5th driven gear using ST.
(C) Thrust bearing (25 × 37.5 × 3)
(D) Washer No. 2 (25 × 37.5 × 4)
ST 499857000 5TH DRIVEN GEAR
(E) Needle bearing (25 × 30 × 20)
REMOVER
(F) Drive pinion collar
(G) Needle bearing (30 × 37 × 23)
(H) Thrust bearing (33 × 50 × 3)

G3M0609

3) Remove woodruff key.

28
 SERVICE PROCEDURE [W3B1] 3-1
3. Drive Pinion Assembly

4) Remove roller bearing (42 × 74 × 40), 3rd-4th 7) Remove 1st driven gear, 2nd gear bushing,
driven gear using ST1 and ST2. gear and hub using ST1 and ST2.
ST1 499757002 SNAP RING PRESS NOTE:
ST2 899714110 REMOVER 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 before-
hand.
ST1 499757002 SNAP RING PRESS
ST2 899714110 REMOVER

G3M0610

5) Remove the key.

6) Remove 2nd driven gear, inner baulk ring, syn-
chro cone and outer baulk ring.

G3M0611

8) Remove sub gear for 1st driven gear.

B: ASSEMBLY
1. GEAR AND HUB ASSEMBLY
Assemble gear and hub assembly.
S3M0445A NOTE:
I Use new gear and hub assembly, if gear or hub
(A) 2nd driven gear
have been replaced.
(B) Inner baulk ring
I Be sure the insert keys are correctly located in
(C) Synchro cone
(D) Outer baulk ring
the insert key grooves inside the reverse driven
gear.

B3M0431B

(A) Key grooves

(B) Reverse driven gear

29
3-1 [W3B2] SERVICE PROCEDURE
3. Drive Pinion Assembly

4) Install 2nd driven gear, inner baulk ring, syn-

chro cone, outer baulk ring and insert onto driven
shaft.

B3M0077E

(A) 1st gear side

(B) 2nd gear side
S3M0445A
(C) Flush surface
(D) Stepped surface (A) 2nd driven gear
(B) Inner baulk ring
2. DRIVEN GEAR ASSEMBLY (C) Synchro cone
1) Install sub gear to 1st driven gear. (D) Outer baulk ring
2) Install 1st driven gear, 1st baulk ring, gear and
hub assembly onto driven shaft. 5) After installing key on driven shaft, install 3rd-
4th driven gear using ST and press.
NOTE:
I Take care to install gear and hub assembly in CAUTION:
proper direction. Do not apply pressure in excess of 10 kN (1 ton,
I Align baulk ring and gear & hub assembly with 1.1 US ton, 1.0 Imp ton).
key groove. NOTE:
3) Install 2nd driven gear bushing onto driven Align groove in baulk ring with insert.
shaft using ST1, ST2 and press. ST 499277200 INSTALLER
CAUTION:
I Attach a cloth to the end of driven shaft to
prevent damage.
I Do not apply pressure in excess of 10 kN (1
ton, 1.1 US ton, 1.0 Imp ton).
NOTE:
When press fitting, align oil holes of shaft and
bush.
ST1 499277200 INSTALLER
ST2 499587000 INSTALLER G3M0615

B3M0078E

(A) Cloth

30
 SERVICE PROCEDURE [W3B3] 3-1
3. Drive Pinion Assembly

6) Install a set of roller bearings (42 × 74 × 40) NOTE:

onto the driven shaft using ST and press. I Stake lock nut at two points.
CAUTION: I Using spring balancer, check that starting torque
Do not apply pressure in excess of 10 kN (1 ton, of roller bearing is 0.1 to 1.5 N·m (0.01 to 0.15
1.1 US ton, 1.0 Imp ton). kg-m, 0.07 to 1.1 ft-lb).

ST 499277200 INSTALLER

S3M0473A

G3M0616 (A) Roller bearing

(B) Spring balancer
7) Position woodruff key in groove on the rear of
driven shaft. Install 5th driven gear onto drive shaft 3. DRIVE PINION SHAFT
using ST and press. 1) Install roller bearing and washer (33 × 50 × 5)
CAUTION: onto drive pinion, using ST1, ST2 and press.
Do not apply pressure in excess of 10 kN (1 ton, CAUTION:
1.1 US ton, 1.0 Imp ton). Do not apply pressure in excess of 10 kN (1 ton,
ST 499277200 INSTALLER 1.1 US ton, 1.0 Imp ton).
ST1 499277100 BUSH 1-2 INSTALLER
ST2 499277200 INSTALLER

G3M0617

8) Install lock washer (42 × 53 × 2). Install lock nut

(42 × 13) and tighten to the specified torque using B3M0080D

ST.
ST 499987300 SOCKET WRENCH (50)
Tightening torque:
265±10 N·m (27±1 kg-m, 195±7 ft-lb)

G3M0618

31
3-1 [W3B3] SERVICE PROCEDURE
3. Drive Pinion Assembly

NOTE: 3) Install drive pinion collar, needle bearing,

When installing roller bearing, note its directions adjusting washer No. 2, thrust bearing, adjusting
(front and rear) because knock pin hole in outer washer No. 1 and differential bevel gear sleeve in
race is offset. that order.
NOTE:
Be careful because spacer must be installed in
proper direction.

B3M0081D

(A) Roller bearing

(B) Knock pin hole
B3M0083D
2) Install thrust bearing (33 × 50 × 3) and needle
bearing (30 × 37 × 23). Install driven shaft assem- (A) Driven shaft
bly. (B) Drive shaft
(C) Drive pinion collar
(D) Needle bearing (25 × 30 × 20)
(E) Washer No. 2 (25 × 36 × 4)
(F) Thrust bearing (25 × 37.5 × 3)
(G) Washer No. 1 (25 × 36 × t)
(H) Differential bevel gear sleeve

S3M0475A

(A) Driven shaft ASSY

32
 SERVICE PROCEDURE [W3C1] 3-1
3. Drive Pinion Assembly

C: ADJUSTMENT 3) After removing ST2, measure starting torque

using torque driver.
1. THRUST BEARING PRELOAD ST1 899884100 HOLDER
1) After completing the preceding steps 1) through ST3 899988608 SOCKET WRENCH (27)
3), select adjusting washer No. 1 so that dimension Starting torque:
(H) is zero through visual check. Position washer 54±25 N·m (5.5±2.5 kg-m, 40±18 ft-lb)
(18.3 × 30 × 4) and lock washer (18 × 30 × 2) and
install lock nut (18 × 13.5).

S3M0476A

(A) Torque driver

4) If starting torque is not within specified limit,

select new adjusting washer No. 1 and recheck
starting torque.

B3M0538A

2) Using ST1, ST2 and ST3, tighten lock nut to the

specified torque.
ST1 899884100 HOLDER B3M0536I

ST2 498427100 STOPPER (A) Adjusting washer No. 1

ST3 899988608 SOCKET WRENCH (27) (B) Adjusting washer No. 2
Tightening torque:
118±8 N·m (12±0.8 kg-m, 86.8±5.8 ft-lb) Adjusting washer No. 1
Part No. Thickness mm (in)
803025051 3.925 (0.1545)
803025052 3.950 (0.1555)
803025053 3.975 (0.1565)
803025054 4.000 (0.1575)
803025055 4.025 (0.1585)
803025056 4.050 (0.1594)
803025057 4.075 (0.1604)

G3M0626

33
3-1 [W4A0] SERVICE PROCEDURE
4. Main Shaft Assembly

5) If specified starting torque range cannot be 4. Main Shaft Assembly

obtained when a No. 1 adjusting washer is used,
then select a suitable No. 2 adjusting washer from A: DISASSEMBLY
those listed in the following table. Repeat steps 1)
1) Put vinyl tape around main shaft splines to pro-
through 4) to adjust starting torque.
tect oil seal from damage. Then pull out oil seal
and needle bearing by hand.
2) Remove lock nut from transmission main shaft
assembly.
NOTE:
Remove caulking before taking off lock nut.
ST1 498937000 TRANSMISSION HOLDER
ST2 499987003 SOCKET WRENCH (35)

B3M0536I

(A) Adjusting washer No. 1

(B) Adjusting washer No. 2

Starting torque Dimension H Washer No. 2

Low Small Select thicker one.
High Large Select thinner one.

Adjusting washer No. 2 B3M0439A

Part No. Thickness mm (in)
3) Remove 5th-Rev sleeve and hub assembly,
803025059 3.850 (0.1516)
baulk ring, 5th drive gear and needle bearing (32
803025054 4.000 (0.1575) × 36 × 25.7).
803025058 4.150 (0.1634)

6) Recheck that starting torque is within specified

range, then clinch lock nut at four positions.

B3M0437B

(A) 5th-Rev sleeve and hub ASSY

(B) Baulk ring
(C) 5th drive gear

34