Part 1

Transmission Assemble

Special Tools

J 35405 - Differential Preload Wrench




1. Coat the sliding and rotating surfaces of the front differential side gear with gear oil.
2. Install the front No. 1 differential side gear thrust washers onto the front differential side gears.

Note: While rotating the front differential side gear, install the front differential pinions and front differential pinion thrust washers.

3. Install the front differential side gears, front differential pinions, and front differential pinion thrust washers onto the front differential case.




4. Coat the front No. 1 differential pinion shaft with MP grease.
5. Install the front No. 1 differential pinion shaft onto the front differential case so that the hole for the front differential pinion shaft straight pin is aligned with the hole in the front differential case.




6. Adjust the front differential side gear backlash.
7. Install the front differential pinion to the front differential case side. Using a dial indicator, measure the front differential side gear backlash.

Standard Backlash: 0.05-0.20 mm (0.0020-0.0079 in)

8. If the backlash is out of the specification, replace the side gear thrust washers.




9. Using a pin punch (3 mm) and a hammer, install the front differential pinion shaft straight pin onto the front differential case.




10. Using a chisel and a hammer, stake the front differential case hole.




11. Clean the contact surfaces of the front differential case and ring gear.
12. Using a heater, heat the front differential ring gear to 90-100°C (194-230°F).
13. After the moisture on the ring gear has completely evaporated, quickly install the ring gear onto the differential case.




14. Aligning the matchmarks (1), quickly install the front differential ring gear onto the front differential case.

Caution: Refer to Fastener Caution (Fastener Caution)

15. Install the bolts and tighten to 77 Nm (57 lb ft).




16. Install the speedometer drive gear onto the front differential case.




17. Coat the No. 2 transmission hub sleeve with gear oil.
18. Install the synchromesh shifting key springs and synchromesh shifting keys to the No. 2 transmission clutch hub.





Note: Position the No. 2 transmission hub sleeve and No. 2 transmission clutch hub correctly together.

19. Install the No. 2 transmission clutch hub onto the No. 2 transmission hub sleeve.




20. Coat the 3rd gear needle roller bearing with gear oil and install it onto the input shaft.




21. Coat the 3rd gear with gear oil and install it onto the input shaft.




22. Coat the 3rd gear synchronizer ring with gear oil and install it onto the 3rd gear.





Note: Fit the synchromesh shifting keys into the grooves of the synchronizer ring correctly.

23. Using a press, install the No. 2 transmission clutch hub (1) onto the input shaft.




24. Select a snap ring that will allow minimum axial play. Refer to Manual Transmission Specifications (Manual Transmission Specifications) for Snap Ring Thickness 1.

Standard Clearance: 0.1 mm (0.0039 in) or less

25. Using a brass bar and a hammer, install the snap ring onto the input shaft.




26. Coat the 4th gear synchronizer ring with gear oil and install it onto the No. 2 transmission clutch hub.




27. Coat the 4th gear needle roller bearing and 4th gear bearing spacer with gear oil and install them onto the No. 2 transmission clutch hub.




28. Coat the 4th gear with gear oil and install it onto the input shaft.




29. Using a press (1), install the input shaft rear radial ball bearing onto the input shaft.




30. Select a snap ring that will allow minimum axial play. Refer to Manual Transmission Specifications (Manual Transmission Specifications) for Snap Ring Thickness 2.

Standard Clearance: 0.1 mm (0.0039 in) or less

Note: Do not damage the journal surface of the snap ring.

31. Using a brass bar and a hammer, install the snap ring onto the input shaft.
32. Inspect the 3rd gear radial clearance.




33. Using a dial indicator, measure the 3rd gear radial clearance.

* Standard clearance, NSK made bearing - 0.015-0.056 mm (0.0005-0.0022 in)
* Standard clearance, KOYO made bearing - 0.015-0.058 mm (0.0005-0.0022 in)
* Maximum clearance, NSK made bearing - 0.056 mm (0.0022 in)
* Maximum clearance, KOYO made bearing - 0.058 mm (0.0022 in)

34. If the clearance exceeds the maximum, replace the 3rd gear, 3rd gear needle roller bearing or input shaft.
35. Inspect the 4th gear radial clearance.




36. Using a dial indicator, measure the 4th gear radial clearance between the gear and shaft.

* Standard clearance, NSK made bearing - 0.009-0.050 mm (0.0003-0.0019 in)
* Standard clearance, KOYO made bearing - 0.009-0.050 mm (0.0003-0.0019 in)
* Maximum clearance, NSK made bearing - 0.050 mm (0.0019 in)
* Maximum clearance, KOYO made bearing - 0.050 mm (0.0019 in)

37. If the clearance exceeds the maximum, replace the 4th gear, 4th gear needle roller bearing or input shaft.
38. Inspect the 3rd gear thrust clearance.




39. Using a dial indicator, measure the 3rd gear thrust clearance.

* Standard clearance - 0.10-0.35 mm (0.0039-0.0138 in)
* Maximum clearance - 0.35 mm (0.0138 in)

40. If the clearance exceeds the maximum, replace the No. 2 transmission clutch hub, 3rd gear or input shaft.




41. Inspect the 4th gear thrust clearance.
42. Using a feeler gage, measure the 4th gear thrust clearance.

* Standard clearance - 0.10-0.55 mm (0.0039-0.0217 in)
* Maximum clearance - 0.55 mm (0.0217 in)

43. If the clearance exceeds the maximum, replace the No. 2 transmission clutch hub, 4th gear or input shaft rear radial ball bearing.




44. Inspect the reverse gear.
45. Using vernier calipers, measure the width of the reverse gear groove (a) and the thickness of the claw part on the reverse shift fork (b), and calculate the clearance.

Standard Clearance (a-b): 0.15-0.35 mm (0.0059-0.0138 in)

46. If the clearance is out of the specification, replace the reverse gear and reverse shift fork.




47. Inspect that the No. 1 transmission clutch hub and reverse gear slide smoothly.
48. Inspect that the edges of the reverse gear spline gear are not worn down.




49. Coat the reverse gear and No. 1 transmission clutch hub with gear oil.
50. Install the synchromesh shifting key springs and synchromesh keys to the No. 1 transmission clutch hub.