Removal and Installation
REMOVAL1. Remove the manual transmission assembly from vehicle.
2. Remove transfer case with extension case assembly.
3. Remove transmission case.
4. Remove drive pinion shaft assembly.
NOTE: Use a hammer handle, etc. to remove if too tight.
INSTALLATION
1. Remove differential assembly.
2. Alignment marks/numbers on hypoid gear set
The upper number on driven pinion is the match number for combining it with hypoid driven gear. The lower number is for shim adjustment. If no lower number is shown, the value is zero. The number on hypoid driven gear indicates a number for combination with drive pinion.
3. Place drive pinion shaft assembly on right hand transmission main case without shim and tighten bearing mounting bolts.
4. Inspection and adjustment of ST
NOTE:
^ Loosen the two bolts and adjust so that the scale indicates 0.5 correctly when the plate end and the scale end are on the same level.
^ Tighten the two bolts.
ST 499917500 DRIVE PINION GAUGE ASSY
5. Position the ST by inserting the knock pin of ST into the knock: hole in the transmission case.
ST 499917500 DRIVE PINION GAUGE ASSY
6. Slide the drive pinion gauge scale with fingertip and read the value at the point where it matches with the end face of drive pinion.
ST 499917500 DRIVE PINION GAUGE ASSY
7. The thickness of shim shall be determined by adding the value indicated on drive pinion to the value indicated on the ST. (Add if the number on drive pinion is prefixed by + and subtract if the number is prefixed by -.)
ST 499917500 DRIVE PINION GAUGE ASSY
8. Select one to three shims from the next table for the value determined as described above and take a shim thickness, which is closest to the said value.
9. Install differential assembly.
10. Set transmission main shaft assembly and drive pinion assembly in position. (So there is no clearance between the two when moved all the way to the front). Inspect suitable 1st-2nd, 3rd -4th and 5th shifter fork so that coupling sleeve and reverse driven gear are positioned in the center of their synchronizing mechanisms.
11. Install transmission case.
12. Install transfer case with extension case assembly.
13. Install the manual transmission assembly to vehicle.