Counter Shaft

COUNTER SHAFT

COMPONENTS (Part 1):

COMPONENTS (Part 2):

DISASSEMBLY

1. REMOVE UNDERDRIVE PLANETARY SUN GEAR SUB-ASSEMBLY
(a) Remove the underdrive planetary sun gear sub-assembly from the counter shaft assembly.

2. REMOVE UNDERDRIVE PLANETARY SUN GEAR HOLE SNAP RING
(a) Using snap ring pliers, remove the underdrive planetary sun gear hole snap ring from the underdrive planetary sun gear sub-assembly.

3. REMOVE UNDERDRIVE PLANETARY GEAR HOLE SNAP RING
(a) Using a screwdriver, remove the underdrive planetary gear hole snap ring from the counter shaft assembly.

4. REMOVE UNDERDRIVE PLANETARY GEAR ASSEMBLY
(a) Remove the underdrive planetary gear assembly from the counter shaft assembly.

5. REMOVE UNDERDRIVE INPUT SHAFT NEEDLE ROLLER BEARING
(a) Remove the underdrive input shaft needle roller bearing from the counter shaft assembly.

6. REMOVE UNDERDRIVE INPUT SHAFT THRUST BEARING RACE
(a) Remove the underdrive input shaft thrust bearing race from the counter shaft assembly.

7. INSPECT COUNTER SHAFT ASSEMBLY

8. REMOVE UNDERDRIVE INPUT SHAFT NUT
(a) Using a chisel and hammer, unstake the underdrive input shaft nut.

(b) Using SST, remove the underdrive input shaft nut.
SST 09350-32014 (09351-32170)

9. REMOVE DIFFERENTIAL DRIVE PINION
(a) Using SST, remove the differential drive pinion with output differential drive pinion, underdrive cylinder roller bearing and front drive pinion front tapered roller bearing.
SST 09950-40011 (09951-04010, 09952-04010, 09953-04030, 09954-04010, 09955-04061, 09957-04010, 09958-04011)

(b) Remove the front differential drive pinion bearing spacer from the counter shaft assembly.

10. REMOVE UNDERDRIVE PLANETARY RING GEAR
(a) Using a screwdriver, remove the snap ring from the counter shaft assembly.

(b) Remove the underdrive planetary ring gear from the counter shaft assembly.

11. REMOVE FRONT DRIVE PINION REAR TAPERED ROLLER BEARING
(a) Using SST and a press, remove the front drive pinion rear tapered roller bearing from the counter shaft assembly.
SST 09950-00020

(b) Using a brass bar and hammer, tap out the front drive pinion rear tapered roller bearing outer race.

12. INSPECT UNDERDRIVE PLANETARY SUN GEAR SUB-ASSEMBLY
13. INSPECT UNDERDRIVE PLANETARY GEAR ASSEMBLY

INSPECTION

1. INSPECT COUNTER SHAFT ASSEMBLY
(a) Using soft jaws, hold the differential drive pinion by a vise.
(b) Using SST and spring tension gauge, measure the starting torque of the counter shaft assembly.
SST 09350-32014 (09351-32170)
Starting torque:
with spring tension gauge 1.2 to 2.0 kg (2.6 to 4.4 lb)
with torque wrench (hexagon nut side)
Torque:
New bearing 0.6 to 1.0 Nm (6 to 10 kgf/cm, 5.2 to 8.7 in. lbs.)
Reused bearing 0.3 to 0.5 Nm (3 to 5 kgf/cm, 2.6 to 4.3 in. lbs.)

If the torque exceeds the limit, replace the spacer.

2. INSPECT UNDERDRIVE PLANETARY SUN GEAR SUB-ASSEMBLY
(a) Using a caliper gauge, measure the bushing inside diameter of the underdrive planetary sun gear sub-assembly as shown in the illustration.
Standard inside diameter: 29.800 to 29.825 mm (1.17323 to 1.17421 in.)
Maximum inside diameter: 29.870 mm (1.17598 in.)

3. INSPECT UNDERDRIVE PLANETARY GEAR ASSEMBLY
(a) Using a feeler gauge, measure the planetary pinion gear thrust clearance.
Standard clearance: 0.2 to 0.5 mm (0.008 to 0.020 in.)
Maximum clearance: 0.5 mm (0.020 in.)

If the clearance is greater than the maximum, replace the underdrive planetary gear assembly.

REASSEMBLY

1. INSTALL FRONT DRIVE PINION REAR TAPERED ROLLER BEARING
(a) Using SST and a press, press in the front drive pinion rear tapered roller bearing of the thick inner race side.

(b) Using SST and a press, press in the thick front drive pinion rear tapered roller bearing outer race to the flange side of the differential drive pinion.

(c) Using SST and a press, press in the thick front drive pinion front tapered roller bearing race to the other side.
SST 09350-32014 (09351-32180)

2. INSTALL UNDERDRIVE PLANETARY RING GEAR
(a) Install the underdrive planetary ring gear to the counter shaft assembly.

(b) Install the snap ring to the counter shaft assembly.
SST 09350-32014 (09351-32090, 09351-32180, 09351-32150)

3. INSTALL DIFFERENTIAL DRIVE PINION
(a) Install a new front differential drive pinion bearing spacer to the counter shaft assembly.

(b) Install the differential drive pinion to the counter shaft assembly.

4. INSTALL FRONT DRIVE PINION FRONT TAPERED ROLLER BEARING
(a) Using SST and a press, press in the another front drive pinion front tapered roller bearing.
SST 09350-32014 (09351-32180)

NOTICE: Be sure there is some clearance between the output flange and bearing.

5. INSTALL UNDERDRIVE CYLINDRICAL ROLLER BEARING
(a) Using SST and a press, press in the underdrive cylinder roller bearing.
SST 09350-32014 (09351-32180)

NOTICE: Be sure there is some clearance.

6. ADJUST COUNTER SHAFT ASSEMBLY
(a) Using SST and a press, press in the counter driven gear to the counter shaft assembly.
SST 09350-32014 (09351-32100)

(b) Install SST to the counter driven gear.
SST 09350-32014 (09351-32032)

(d) Temporarily install a new lock nut, and using SST, tighten the underdrive input shaft nut until the counter shaft starting torque comes to the specified value.
SST 09350-32014 (09351-32170)
Torque:
(Reference) 180 Nm (1,835 kgf/cm, 132 ft. lbs.)
(e) Use a torque wrench with a fulcrum length of 42 cm (16.54 in.).

(f) Using soft jaws, hold the drive pinion by a vise.
(g) Using SST and spring tension gauge, measure the starting torque of the counter shaft assembly.
SST 09350-32014 (09351-32170)
Starting torque:
with tension gauge 1.2 to 2.0 kg (2.6 to 4.4 lb)
with torque wrench (hexagon nut side)
Torque:
New bearing 0.6 to 1.0 Nm (6 to 10 kgf/cm, 5.2 to 8.7 in. lbs.)
Reused bearing 0.3 to 0.5 Nm (3 to 5 kgf/cm, 2.6 to 4.3 in. lbs.)

If the starting torque exceeds the limit, replace the spacer and retorque.

HINT: Before measuring the starting torque, snug down the bearing by turning the counter shaft.

(h) Using a punch and hammer, stake the underdrive input shaft nut.

(i) Remove SST from the counter driven gear.
SST 09350-32014 (09351-32032)

(j) Using SST, remove the counter driven gear from the counter shaft assembly.
SST 09350-32014 (09351-32061)

7. INSTALL UNDERDRIVE INPUT SHAFT THRUST BEARING RACE
(a) Coast the underdrive input shaft thrust bearing race with petroleum jelly and install them to the counter shaft assembly.

Race: mm (in.):

8. INSTALL UNDERDRIVE INPUT SHAFT NEEDLE ROLLER BEARING
(a) Coat the underdrive input shaft needle roller bearing with petroleum jelly and install them to the counter shaft assembly.

Bearing: mm (in.):

9. INSTALL UNDERDRIVE PLANETARY GEAR ASSEMBLY
(a) Install the underdrive planetary gear assembly to the counter shaft assembly.

(b) Install the underdrive planetary gear hole snap ring to the counter shaft assembly.

10. INSTALL UNDERDRIVE PLANETARY SUN GEAR HOLE SNAP RING
(a) Using snap ring pliers, install the underdrive planetary sun gear hole snap ring to the underdrive planetary sun gear sub-assembly.

11. INSTALL UNDERDRIVE PLANETARY SUN GEAR SUB-ASSEMBLY
(a) Install the underdrive planetary sun gear sub-assembly to the counter shaft assembly.