1. Install the sleeve and the gear and hub assembly by matching the alignment marks.
NOTE:
• Make sure that there is no large clearance at both sides of ball detent after assembly. (Except for 1.5 L model)
|
(A) |
Ball detent |
|
(B) |
1st-2nd synchronizer hub |
|
(C) |
Reverse driven gear |
|
(D) |
There is no large clearance at this section |
• Use the new gear & hub assembly, if replacing the gear or hub.
|
(A) |
1st gear side |
|
(B) |
2nd gear side |
|
(C) |
Flush surface |
|
(D) |
Stepped surface |
2. Install the 1st driven gear, inner baulk ring, synchro cone, outer baulk ring, and gear & hub assembly onto driven shaft.
• Except for 1.5 L model
|
(A) |
1st driven gear |
|
(B) |
Synchro cone |
|
(C) |
Inner baulk ring |
|
(D) |
Outer baulk ring |
• 1.5 L model
|
(A) |
1st driven gear |
|
(B) |
1st baulk ring |
|
(C) |
Gear & hub ASSY |
|
(D) |
2nd gear bushing |
NOTE:
• Take care to install the gear and hub assembly in proper direction.
• Align the baulk ring and gear & hub assembly with the key groove.
3. Install the 2nd driven gear bushing onto driven shaft using ST1, ST2 and a press.
CAUTION:
Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
NOTE:
• Attach a cloth to the end of the driven shaft to prevent damage.
• When press fitting, align the oil holes of the shaft and bushing
| ST1 499277200 | INSTALLER |
| ST2 499587000 | INSTALLER |
4. Install the 2nd driven gear, inner baulk ring, synchro cone and outer baulk ring, and insert them onto driven shaft.
• 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 |
5. After installing key on driven shaft, install the 3rd-4th driven gear using an ST and a press.
CAUTION:
Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
NOTE:
Align the groove in baulk ring with the insert.
| ST 499277200 | INSTALLER |
6. Install a set of roller bearings onto the driven shaft using ST and a press.
CAUTION:
Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
| ST 499277200 | INSTALLER |
7. Position the woodruff key in groove of the rear of driven shaft. Install the 5th driven gear onto driven shaft using ST and a press.
CAUTION:
Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
| ST 499277200 | INSTALLER |
8. Install the lock washer. Tighten the lock nuts to the specified torque using ST1 and ST2.
| ST1 499987300 | SOCKET WRENCH (50) |
| ST2 899884100 | HOLDER |
Tightening torque:
260 N·m (26.5 kgf-m, 191.8 ft-lb)
NOTE:
• Use new lock nuts and lock washers.
• Crimp the locknut in 2 locations.
• Using a spring scale, check that starting torque of the roller bearing is 0.1 to 1.5 N (0.01 to 0.15 kgf, 0.02 to 0.34 lbf).
9. Install the roller bearing onto the drive pinion shaft.
NOTE:
When installing the roller bearing, note its directions (front and rear) because the knock pin hole of outer race is offset.
|
(A) |
Roller bearing |
|
(B) |
Knock pin hole |
10. Install the washer using ST1, ST2 and a press.
CAUTION:
Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
| ST1 499277100 | BUSHING 1-2 INSTALLER |
| ST2 499277200 | INSTALLER |
|
(A) |
Washer |
11. Install the thrust bearing and needle bearing. Install the driven shaft assembly.
12. 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 to install the spacer in the proper direction.
|
(A) |
Driven shaft |
|
(B) |
Drive shaft |
|
(C) |
Drive pinion collar |
|
(D) |
Needle bearing (25 × 30 × 20) |
|
(E) |
Adjusting washer No. 2 (25 × 36 × t) |
|
(F) |
Thrust bearing (25 × 37.5 × 3) |
|
(G) |
Adjusting washer No. 1 (25 × 36 × t) |
|
(H) |
Differential bevel gear sleeve |
13. Adjust the thrust bearing preload. 
1. Install the individual gear & hub assemblies.
NOTE:
• Use the new gear and hub assembly, if replacing the gear or hub.
• Make sure that the insert key is attached properly in the insert key groove of the reverse driven gear.
|
(A) |
Key groove |
|
(B) |
Reverse driven gear |
|
(C) |
1st driven gear side |
|
(D) |
2nd driven gear side |
|
(E) |
Flush surface |
|
(F) |
Stepped surface |
2. Use ST1 and ST2 to press-fit the 1st driven gear thrust washer and roller bearing onto the drive pinion shaft.
NOTE:
Use a new roller bearing and 1st gear thrust washer.
| ST1 499877000 | RACE 4-5 INSTALLER |
| ST2 499277100 | BUSHING 1-2 INSTALLER |
|
(A) |
Thrust washer |
3. Attach the 1st driven gear bushing to the drive pinion shaft.
CAUTION:
Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
| ST1 499877000 | RACE 4-5 INSTALLER |
| ST2 499277100 | BUSHING 1-2 INSTALLER |
|
(A) |
1st driven gear bushing |
4. Measure the outer diameter of the 1st driven gear bushing, and determine an appropriate 1st driven gear.
|
1st driven gear | |
|
Part No. |
Bushing outer diameter mm (in) |
|
32231AA841 |
42.019 — 42.033 (1.6543 — 1.6548) |
|
32231AA851 |
42.005 — 42.018 (1.6537 — 1.6543) |
|
32231AA861 |
41.990 — 42.004 (1.6531 — 1.6537) |
5. Attach the 1st driven gear, 1st-2nd baulk ring and the gear & hub assembly (already attached) to the drive pinion shaft by hand.
NOTE:
Insert along the groove of the ring.
6. Use ST1 and ST2 to attach the 2nd driven gear bushing onto the drive pinion shaft.
CAUTION:
Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
| ST1 499877000 | RACE 4-5 INSTALLER |
| ST2 499277100 | BUSHING 1-2 INSTALLER |
|
(A) |
2nd driven gear bushing |
7. Install the 2nd driven gear, inner baulk ring, synchro cone and outer baulk ring to the drive pinion shaft.
8. Attach the key to the drive pinion shaft groove, and attach the 3rd-4th driven gear.
CAUTION:
Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
| ST 499877000 | RACE 4-5 INSTALLER |
|
(A) |
3rd-4th driven gear |
9. Using the ST, attach the ball bearing (29 × 74 × 38) to the drive pinion shaft.
CAUTION:
Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
| ST 499277100 | BUSHING 1-2 INSTALLER |
10. Position the woodruff key in the groove at the rear end of the drive pinion shaft. Install the 5th driven gear onto the drive shaft using ST and a press.
CAUTION:
• Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
• Point the 5th driven gear in the proper direction.
• Be careful that the woodruff key does not move out of position while attaching the 5th driven gear.
| ST 499277100 | BUSHING 1-2 INSTALLER |
|
(A) |
Rear |
11. Attach the lock washer, and tighten the lock nuts to the specified torque using ST1 and ST2.
CAUTION:
Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
NOTE:
• Use new lock nuts and lock washers.
• Crimp in 4 locations to fix the locknut in place.
| ST1 499987003 | SOCKET WRENCH (35) |
| ST2 899884100 | HOLDER |
Tightening torque:
120 N·m (12.2 kgf-m, 88.5 ft-lb)
