Part 2 of 2
INTERMEDIATE GEAR - DISASSEMBLY AND REASSEMBLY
DISASSEMBLY SERVICE POINTS
Tapered Roller Bearing:
Ball Bearing:
A - BALL BEARING/TAPER ROLLER BEARING/1st SPEED GEAR REMOVAL
CAUTION: Do not reuse the bearing removed from the shaft. Replace the inner and outer races of the taper roller bearing as a set.
B - 1st-2nd SPEED SYNCHRONIZER HUB/2nd SPEED GEAR REMOVAL
C - BALL BEARING REMOVAL
CAUTION: Do not reuse the bearing removed from the shaft.
D - TAPER ROLLER BEARING REMOVAL
CAUTION: Do not reuse the bearing removed from the shaft. Replace the inner and outer races of the taper roller bearing as a set.
INSPECTION
INTERMEDIATE GEAR
1. Check the outer surface of the intermediate gear where the needle bearing is mounted for damage, abnormal wear and seizure [portion A].
2. Check the splines for damage and wear.
NEEDLE BEARING
1. Combine the needle bearing with the shaft or bearing sleeve and gear and check that it rotates smoothly without abnormal noise or play.
2. Check the needle bearing cage for deformation.
SYNCHRONIZER RING
1. Check the clutch gear teeth for damage and breakage.
2. Check the internal surface for damage, wear and broken threads.
3. Force the synchronizer ring toward the clutch gear and check clearance "A". Replace if it is out of specification.
Limit: 0.5 mm (0.02 in.)
SYNCHRONIZER SLEEVE AND HUB
1. Combine the synchronizer sleeve and hub and check that they slide smoothly.
2. Check that the sleeve is free from damage at its inside front and rear ends.
3. Check for wear of the hub end surface (in contact with each speed gear).
CAUTION: When replacing, replace the synchronizer hub and sleeve as a set.
SYNCHRONIZER KEY AND SPRING
1. Check for wear of the synchronizer key center protrusion.
2. Check the spring for weakness, deformation and breakage.
SPEED GEARS
1. Check the bevel gear and clutch gear teeth for damage and wear.
2. Check the synchronizer cone for rough surface, damage and wear.
3. Check the gear bore and front and rear ends for damage and wear.
REASSEMBLY SERVICE POINTS
A - BALL BEARING INSTALLATION
B - TAPER ROLLER BEARING INSTALLATION
CAUTION: When installing the bearing, push the inner race only.
C - 1ST SPEED GEAR, 2ND SPEED GEAR SYNCHRONIZER RINGS INSTALLATION
1. The 1st speed gear and 2nd speed gear synchronizer rings have an. identification mark.
D - 1st-2nd SPEED SYNCHRONIZER HUB/SYNCHRONIZER KEY/1st-2nd SYNCHRONIZER SLEEVE INSTALLATION
1. Combine the 1st-2nd speed synchronizer hub and sleeve as illustrated.
2. The synchronizer sleeve has tooth missing at six portions. Assemble the hub to the sleeve in such a way that the center tooth "T" between two missing teeth will touch the synchronizer key.
E - SYNCHRONIZER SPRING INSTALLATION
1. When installing the synchronizer springs, be sure to position each spring with respect to the keys as illustrated.
F - BEARING SLEEVE INSTALLATION
G - TAPER ROLLER BEARING INSTALLATION
CAUTION: When installing the bearing, push the inner race only.
H - BALL BEARING INSTALLATION
I - SNAP RING INSTALLATION
1. Select and install the snap ring that gives standard intermediate gear bearing end play.
Intermediate gear bearing end play: 0.01-0.14 mm (0.0004-0055 in.)
OUTPUT SHAFT DISASSEMBLY AND REASSEMBLY
DISASSEMBLY SERVICE POINT
A - TAPER ROLLER BEARINGS REMOVAL
CAUTION: Do not reuse the bearings removed from the shaft. Replace the inner and outer races of the taper roller bearing as a set.
REASSEMBLY SERVICE POINT
A - TAPER ROLLER BEARINGS INSTALLATION
CAUTION: When installing the bearing, push the inner race only.
DIFFERENTIAL DISASSEMBLY AND REASSEMBLY
DISASSEMBLY SERVICE POINTS
A - BALL BEARINGS REMOVAL
CAUTION: Do not reuse the bearing removed from the shaft.
B - TAPER ROLLER BEARING REMOVAL
CAUTION: Do not reuse the bearing removed from the shaft. Replace the inner and outer races of the taper roller bearing as a set.
C - LOCK PIN REMOVAL
1. Drive out the lock pin from the hole A using a punch.
REASSEMBLY SERVICE POINTS
A - SPACER/SIDE GEAR/WASHER/PINION/PINION SHAFT INSTALLATION
1. Install the spacer on the back of the side gear and then install the gear in the differential case.
CAUTION: When installing a new side gear, use a spacer of medium thickness [0.93-1.00 mm (0.366-0.394 in.)].
2. Set the washer on the back of each pinion and insert the two pinions to specified position while engaging them with the side gears and turning them.
3. Insert the pinion shaft.
4. Measure the backlash between the side gears and pinions.
Standard value: 0.025-0.150 mm (0.001 -0.006 in.)
5. If the backlash is out of specification, disassemble again and using correct spacer, reassemble and adjust.
CAUTION: Adjust for same backlash of both side gears.
LOCK PIN INSTALLATION
1. Align the pinion shaft lock pin hole with the case lock pin hole and insert the lock pin.
CAUTION:
- Do not reuse the lock pin.
- The lock pin must not protrude more than 3 mm (0.118 in.).
C - TAPER ROLLER BEARINGS INSTALLATION
CAUTION: When press-fitting the bearings, push the inner race only.
D - BALL BEARINGS INSTALLATION
E - BOLTS INSTALLATION
1. Apply specified sealant, 3M Stud Locking No.4170 or equivalent, to the entire threads of the bolts and quickly tighten in the order shown to specified torque.
CAUTION: If a bolt is reused, remove traces of old sealant completely from the threads.
SHIFT FORK DISASSEMBLY AND REASSEMBLY
REASSEMBLY SERVICE POINT
A - INTER LOCK PLUNGER INSTALLATION
SPEEDOMETER DRIVEN GEAR DISASSEMBLY AND REASSEMBLY
A - SPRING PIN INSTALLATION
1. Install the spring pin in such a way that its slit does not face the gear shaft.
CLUTCH HOUSING DISASSEMBLY AND REASSEMBLY
DISASSEMBLY SERVICE POINTS
A - LOCK PIN REMOVAL
CAUTION: When removing the lock pin, turn the control lever to such position that the lock pin will not contact the clutch housing.
B - SPRING PIN REMOVAL
CAUTION: When removing the spring pin, pull the control shaft in the direction illustrated so that the spring pin will not contact the clutch housing.
C - NEEDLE BEARING REMOVAL
REASSEMBLY SERVICE POINTS
A - NEEDLE BEARINGS INSTALLATION
1. Install the needle bearing flush with the surface A of the clutch housing using a socket wrench.
2. Install with the part type stamped side facing the surface A.
B - OIL SEAL INSTALLATION
C - SPRING PIN/LOCK PIN INSTALLATION
CAUTION: Do not reuse the spring pin and lock pin. Install the spring pin in such a way that its slit will be at right angle to the control shaft center.