FREE REPAIR MANUALS & LABOR GUIDES 1982-2013 Vehicles
Courtesy of Operation CHARM: Car repair manuals for everyone.

Drive Pinion Shaft Assembly

Drive Pinion Shaft Assembly

REMOVAL
1. Remove the manual transmission assembly from vehicle.
2. Remove the transfer case with extension case assembly.
3. Remove the transmission case.





4. Remove the drive pinion shaft assembly.

NOTE: Use a hammer handle, etc. to remove if too tight.

INSTALLATION
1. Remove the differential assembly.





2. Alignment marks/numbers on hypoid gear set:
Use hypoid driven gear of its match number corresponding with upper one on the drive pinion (A).
The figure (B) shows a number for shim adjustment. If no number is shown, the value is zero.
3. Place the drive pinion shaft assembly on the transmission main case RH without shim and tighten the 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 finger tip 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 in the next table for the value determined as described above, and take the shim(s)) which thickness is closest to the said value.
9. Install the differential assembly.
10. Set the transmission main shaft assembly for single-range and drive pinion assembly in position (So there is no clearance between these two when moved all the way to the front). Inspect the suitable 1st-2nd, 3rd-4th and 5th shifter fork so that the coupling sleeve and reverse driven gear are positioned in the center of their synchronizing mechanisms.
11. Install the transmission case.
12. Install the transfer case with extension case assembly.
13. Install the manual transmission assembly to vehicle.

DISASSEMBLY

NOTE: Attach a cloth to the end of driven shaft (on the frictional side of thrust needle bearing) to prevent damage during disassembly or reassembly.





1. Unlock the caulking of lock nut. Remove the lock nut using ST1, ST2 and ST3.
ST1 899884100 HOLDER
ST2 498427100 STOPPER
ST3 899988608 SOCKET WRENCH (27)
2. Draw out the drive pinion from driven shaft.





Remove the differential bevel gear sleeve, adjusting washer No. 1, adjusting washer No. 2, thrust bearing, needle bearing and drive pinion collar.





3. Remove the roller bearing and washer using ST and press.

NOTE: Do not reuse the roller bearing.

ST 498077000 REMOVER





4. Unlock the caulking of lock nut. Remove the lock nut using ST1 and ST2.
ST1 499987300 SOCKET WRENCH (50)
ST2 899884100 HOLDER





5. Remove the 5th driven gear using ST.
ST 499857000 5TH DRIVEN GEAR REMOVER
6. Remove the woodruff key.





7. Remove the roller bearing and 3rd-4th driven gear using ST1 and ST2.
ST1 499757002 INSTALLER
ST2 899714110 REMOVER
8. Remove the key.





9. Remove the 2nd driven gear, inner baulk ring, synchro cone and outer baulk ring.





10. Remove the 1st driven gear, 2nd gear bushing, gear and hub using ST1 and ST2. (Non-turbo model).





11. Remove the 1st driven gear, inner baulk ring, synchro cone, outer baulk ring, 2nd gear bushing, gear and hub using ST1 and ST2. (Turbo model)





NOTE: Replace the gear and hub if necessary. Do not disassemble because they must engage at a specified point. If they have to be disassembled, mark the engaging point on the spline beforehand.

ST1 499757002 INSTALLER
ST2 899714110 REMOVER

ASSEMBLY





1. Install the sleeve and hub assembly by matching alignment marks.

NOTE: Use the new gear and hub assembly, when replacing the gear or hub.

2. Install the washer to 1st driven gear.





3. Install the 1st driven gear, 1st baulk ring, gear and hub assembly onto driven shaft. (Non-turbo model).





4. Install the 1st driven gear, inner baulk ring, synchro cone, outer baulk ring, gear and hub assembly onto driven shaft. (Turbo model)

NOTE:
- Take care to install the gear and hub assembly in proper direction.
- Align the baulk ring and gear and hub assembly with key groove.





5. Install the 2nd driven gear bushing onto driven shaft using ST1, ST2 and a press.

NOTE:
- Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
- Attach a cloth to the end of driven shaft to prevent damage.
- When press-fitting, align the oil holes of shaft and bushing.

ST1 499277200 INSTALLER
ST2 499587000 INSTALLER





6. Install the 2nd driven gear, inner baulk ring, synchro cone and outer baulk ring, and insert onto driven shaft.





7. After installing the key on driven shaft, install the 3rd-4th driven gear using ST and press.

NOTE:
- Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
- Align the groove in baulk ring with insert.

ST 499277200 INSTALLER





8. Install a set of roller bearings onto the driven shaft using ST and press.

NOTE: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

ST 499277200 INSTALLER





9. Position the woodruff key in groove on the rear of driven shaft. Install the 5th driven gear onto driven shaft using ST and press.

NOTE: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

ST 499277200 INSTALLER





10. Install the lock washer. Install the lock nut and tighten to the specified torque using ST.
ST 499987300 SOCKET WRENCH (50)
Tightening torque: 260 Nm (26.5 kgf-cm, 191.7 ft. lbs.)





NOTE:
- Stake the caulking of lock nut at two points.
- Using a spring balancer, check that starting torque of roller bearing is 0.1 to 1.5 N (0.01 to 0.15 kgs, 0.02 to 0.33 lbs).





11. Install the roller bearing onto drive pinion.

NOTE: When installing roller bearing, note its directions (front and rear) because the knock pin hole in outer race is offset.





12. Install the washer using ST1, ST2 and a press.

NOTE: Do not apply pressure in excess of 10 kN (1 ton,1.1 US ton, 1.0 Imp ton).

ST1 499277100 BUSHING 1-2 INSTALLER
ST2 499277200 INSTALLER





13. Install the thrust bearing and needle bearing. Install the driven shaft assembly.





14. Install the drive pinion collar, needle bearing, adjusting washer No. 2, thrust bearing, adjusting washer No. 1 and differential bevel gear sleeve in this order.

NOTE: Be careful because the spacer must be installed in proper direction.

15. Adjust the thrust bearing preload.

INSPECTION
Disassembled parts should be washed with unleaded gasoline first and then inspected carefully.





1. Bearings
Replace the bearing in following cases:
- When the bearing balls, outer races and inner races are broken or rusty.
- When the bearing is worn.
- When the bearings fail to turn smoothly or emit noise in rotation after gear oil lubrication.
- The ball bearing on the rear side of the drive pinion shaft should be checked for smooth rotation before the drive pinion assembly is disassembled. In this case, because a preload is working on the
bearing, its rotation feels like it is slightly dragging unlike other bearings.
- When bearings have other defects:
2. Bushing (each gear)
Replace the bushings in following cases:
- When the sliding surface is damaged or abnormally worn.
- When the inner wall is abnormally worn.
3. Gears
- Replace gears with new ones if their tooth surfaces are broken, damaged or excessively worn.
- Correct or replace if the cone that contacts the baulk ring is rough or damaged.
- Correct or replace if the inner surface or end face is damaged.





4. Baulk ring Replace the ring in following cases:
- When the inner surface and end face are damaged.
- When the ring inner surface is abnormally or partially worn.
- If the gap between the end faces of ring and the gear splined part is excessively small, check the clearance (A) while pressing the ring against the cone.
Clearance (A): 0.5-1.0 mm (0.020-0.040 inch)
- When the contact surface of synchronizer ring insert is scratched or abnormally worn.





5. Shifting insert key
Replace the insert key if deformed, excessively worn or defective in any way.
6. Oil seal
Replace the oil seal if the lip is deformed, hardened, worn or defective in any way.
7. O-ring
Replace the O-ring if the sealing face is deformed, hardened, damaged, worn, or defective in any way.

ADJUSTMENT

THRUST BEARING PRELOAD





1. Select a suitable adjusting washer No. 1 to adjust dimension (H) to zero through visual check. Position the washer (18.3 x 30 x 4) and lockwasher (18 x 30 x 2) and install the lock nut (18 x 13.5).





2. Using the ST1, ST2 and ST3, tighten new lock nut to the specified torque.
ST1 899884100 HOLDER
ST2 498427100 STOPPER
ST3 899988608 SOCKET WRENCH (27)
Tightening torque: 120 Nm (12.2 kgf-cm, 88.5 ft. lbs.)





3. After removing the ST2, measure the starting torque using torque driver.
ST1 899884100 HOLDER
ST3 899988608 SOCKET WRENCH (27)
Starting torque: 0.3-0.8 Nm (0.03-0.08 kgf-cm, 0.2-0.6 ft. lbs.)








4. If the starting torque is not within the specified limit, select the adjusting washer No. 2 from following table, and recheck the starting torque.











5. When the specified starting cannot be obtained by the adjusting washer No.2, select new adjusting washer No. 1 and recheck starting torque.
6. Recheck that the starting torque is within specified range, then clinch the lock nut at four positions.