NOTE:
Attach a cloth to the end of driven shaft (on the frictional side of the thrust needle bearing) to prevent damage during disassembly or reassembly.
1. Flatten the tab of the lock nut. Remove the lock nut with 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.
|
(A) |
Differential bevel gear sleeve |
|
(B) |
Adjusting washer No. 1 (25 × 37.5 × t) |
|
(C) |
Thrust bearing (25 × 37.5 × 3) |
|
(D) |
Adjusting washer No. 2 (25 × 37.5 × t) |
|
(E) |
Needle bearing (25 × 30 × 20) |
|
(F) |
Drive pinion collar |
|
(G) |
Needle bearing (30 × 37 × 23) |
|
(H) |
Thrust bearing (33 × 50 × 3) |
3. Remove the roller bearing and washer using ST and a press.
NOTE:
Do not reuse the roller bearing.
| ST 498077000 | REMOVER |
4. Flatten the tab of the 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.
• Except for 1.5 L model
|
(A) |
2nd driven gear |
|
(B) |
Synchro cone |
|
(C) |
Inner baulk ring |
|
(D) |
Outer baulk ring |
• 1.5 L model
|
(A) |
2nd driven gear |
|
(B) |
Synchro cone |
|
(C) |
Inner baulk ring |
|
(D) |
Outer baulk ring |
10. Remove the 1st driven gear, 2nd driven gear bushing, and gear & hub assemblies using ST1 and ST2. (1.5 L model)
|
(A) |
1st driven gear |
|
(B) |
Baulk ring |
|
(C) |
Gear & hub ASSY |
|
(D) |
2nd gear bushing |
NOTE:
If necessary, use a new gear and hub assembly as a set, when replacing the gear or hub. Because these must engage at the specified point, avoid disassembly as much as possible. If it must be disassembled, mark the engaging point on the spline beforehand.
| ST1 499757002 | INSTALLER |
| ST2 899714110 | REMOVER |
11. Remove the 1st driven gear, inner baulk ring, synchro cone, outer baulk ring, 2nd gear bushing, gear and hub using ST1 and ST2. (Except for 1.5 L model)
|
(A) |
1st driven gear |
|
(B) |
Synchro cone |
|
(C) |
Inner baulk ring |
|
(D) |
Outer baulk ring |
NOTE:
If necessary, use a new gear and hub assembly as a set, when replacing the gear or hub. Because these must engage at the specified point, avoid disassembly as much as possible. If it must be disassembled, mark the engaging point on the spline beforehand.
| ST1 499757002 | INSTALLER |
| ST2 899714110 | REMOVER |
1. Loosen the lock nut using ST1 and ST2.
| ST1 499987003 | SOCKET WRENCH (35) |
| ST2 899884100 | HOLDER |
NOTE:
Flatten the lock nut tab before removing the lock nut.
2. Remove the 5th driven gear using ST and press.
| ST 499857000 | 5TH DRIVEN GEAR REMOVER |
3. Remove the woodruff key.
4. Remove the roller bearing and 3rd-4th driven gear using ST1 and ST2.
| ST1 499757002 | INSTALLER |
| ST2 899714110 | REMOVER |
5. Remove the 2nd driven gear, inner baulk ring, synchro cone and outer baulk ring.
6. Remove the 3rd-4th driven gear key.
7. Remove the 1st driven gear, 2nd gear bushing, and gear & hub assemblies using ST1 and ST2.
NOTE:
If necessary, use a new gear and hub assembly as a set, when replacing the gear or hub. Because these must engage at the specified point, avoid disassembly as much as possible. If it must be disassembled, mark the engaging point on the spline beforehand.
| ST1 499757002 | INSTALLER |
| ST2 899714110 | REMOVER |
8. Remove the 1st gear bushing, 1st driven gear thrust washer and roller bearing using the ST and press.
CAUTION:
If disassembled, replace roller bearings (41 × 71 × 23).
| ST 498517000 | REPLACER |
|
(A) |
1st gear bushing |