Pinion Gear: Service and Repair

DISASSEMBLY
1. Straighten the staked portion of the lock nut, and remove the lock nut while locking the rear spline portion of the shaft. Then pull off the drive pinion collar. Remove the O-ring





2. Using a press, separate the rear roller bearing and outer race from the shaft.





3. Using a press, separate the front roller bearing from the shaft.

INSPECTION
1. Make sure that all component parts are free of harmful cuts, gouges, and other faults.





ASSEMBLY
1. Measure dimension "A" of the drive pinion shaft.





2. Using a press, force-fit the roller bearing in position. Do not change the relative positions of the outer race and bearing cone.
3. After fining the O-ring to the shaft, attach the drive pinion collar to the shaft. Be careful not to damage the O-ring.
4. Tighten the lock washer and lock nut to 108-118 Nm (80-87 ft.lb)
a. Pay attention to the orientation of lock washer.





b. When using special tool WRENCH (499787100) and torque wrench, tighten it to 88 Nm (65 ft.lb)





5. Measure the starting torque of the bearing. Make sure the starting torque is within the specified range. If out of the allowable range, replace the roller bearing.
Starting torque: 0.3-2.0 Nm (2.6-17.4 ft.lb)

6. Stake the lock nut securely at two places.





7. Measure dimension "B" of the drive pinion shaft.
8. Determine the thickness t (mm) of the drive pinion shim.

t = 6.5 - (B - A)

The number of shims must be three or less.