Part 2

MAINSHAFT AND GEARS
DISASSEMBLY





1. Before disassembly, check 1st and 2nd main gear end plays.





Gear end play: Refer to image.

If not within specification, disassemble and check contact surface of gear, shaft and hub. Check clearance of snap ring groove.





2. Press out mainshaft rear bearing.





3. Remove thrust washer and snap ring.





4. Press out 5th main gear and 4th main gear.





5. Press out 3rd main gear and 2nd main gear.





6. Remove snap ring.





7. Remove 1st & 2nd synchronizer hub and 1st main gear.





8. Remove mainshaft front bearing.

INSPECTION





Gear And Shaft
- Check shaft for cracks, wear or bending.
- Check gears for excessive wear, chips or cracks.





Synchronizer
- Check spline portion of coupling sleeves, hubs and gears for wear or cracks.
- Check baulk rings for cracks or deformation.
- Check insert springs for deformation.





- Measure wear of 1st and 2nd double baulk rings.
a. Place baulk rings in position on synchronizer cone.
b. While holding baulk ring against synchronizer cone as far as it will go, measure dimensions "A" and "B".

Standard:
A 0.6 - 0.8 mm (0.024 - 0.031 inch)
B 0.6 - 1.1 mm (0.024 - 0.043 inch)
Wear limit:
0.2 mm (0.008 inch)

c. If dimension "A" or "B" is smaller than the wear limit, replace baulk ring.





Bearing
- Make sure bearings roll freely and are free from noise, cracks, pitting or wear.
- When replacing tapered roller bearing, replace outer and inner race as a set.





ASSEMBLY









1. Press on 1st main gear, 1st baulk ring and 1st & 2nd synchronizer hub.
- Pay attention to direction of 1st & 2nd synchronizer hub.
2. Select proper snap ring of 1st & 2nd synchronizer hub to minimize clearance of groove and then install it.

Allowable clearance of groove:
0 - 0.1 mm (0 - 0.004 inch)





Snap ring of 1st & 2nd synchronizer hub:
Refer to image.





3. Install 2nd synchronizer cone, inner & outer baulk rings. Insert springs and 1st & 2nd coupling sleeve.
4. Install 2nd main gear.
- Ensure four protrusions of 2nd synchronizer cone are set in holes of 2nd main gear.





5. Press on 3rd main gear.
6. Press on 4th main gear.





7. Press on 5th main gear.
8. Select proper snap ring of 5th main gear to minimize clearance of groove and then install it.

Allowable clearance of groove:
0 - 0.15 mm (0 - 0.0059 inch)





Snap ring of 5th main gear:
Refer to image.





9. Press on thrust washer and press on mainshaft rear bearing.
10. Press on mainshaft front bearing.
11. Measure gear end play as a final check.

FINAL DRIVE
DISASSEMBLY
- RS5F50A -





1. Remove final gear.
2. Remove speedometer drive gear by cutting it.
3. Press out differential side bearings.
- Be careful not to mix up the right and left bearings.





4. Drive out retaining pin and draw out pinion mate shaft.
5. Remove pinion mate gears and side gears.

- RS5F50V-





1. Remove final gear.





2. Press out differential side bearings.





3. Remove speedometer drive gear.





4. Remove viscous coupling.





5. Separate differential cases. Make paint marks to identify their original positions.
6. Remove pinion mate shaft with gears.

INSPECTION





Gear, Washer, Shaft And Case
- Check mating surfaces of differential case, viscous coupling, side gears and pinion mate gears.
- Check washers for wear.





Viscous Coupling
- Check case for cracks.
- Check silicone oil for leakage.





Bearings
- Make sure bearings roll freely and are free from noise, cracks, pitting or wear.
- When replacing taper roller bearing, replace outer and inner race as a set.

ASSEMBLY





1. Attach side gear thrust washers to side gears, then install pinion mate washers and pinion mate gears in place.





2. Insert pinion mate shaft.
- When inserting, be careful not to damage pinion mate thrust washers.

-RS5F50A -





3. Measure clearance between side gear and differential case with washers following the procedure below:
a. Set Tool and dial indicator on side gear.
b. Move side gear up and down to measure dial indicator deflection. Always measure indicator deflection on both side gears.

Clearance between side gear and differential case with washers:
0.1 - 0.2 mm (0.004 - 0.008 inch)





c. If not within specification, adjust clearance by changing thickness of side gear thrust washers.





Side gear thrust washer: Refer to image.





4. Install retaining pin.
- Make sure that retaining pin is flush with case.





5. Install final gear.
6. Install speedometer drive gear.





7. Press on differential side bearings.

- RS5F50V -





3. Measure clearance between side gear and differential case & viscous coupling with washers using the following procedure:

Differential case side
a. Set tool on the differential case and lock gauging cylinder in place with set screw.





b. Install gauging plunger into cylinder.





c. Install pinion mate gears and side gear with thrust washer on differential case.
d. Set tool and allow gauging plunger to rest on side gear thrust washer.
e. Measure gap between plunger and cylinder.
This measurement should give exact clearance between side gear and differential case with washers.

Standard clearance: 0.1 - 0.2 mm (0.004 - 0.008 inch)

f. If not within specification adjust clearance by changing thickness of side gear thrust washer.





Side gear thrust washers for differential case side: Refer to image.