1. Install the sleeve and gear & hub assembly by matching alignment marks.
NOTE:
After installation, make sure there is no significant gap at both sides of the ball detent.
|
(A) |
Ball detent |
|
(B) |
1st-2nd synchronizer hub |
|
(C) |
Reverse driven gear |
|
(D) |
There is no significant gap here. |
NOTE:
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 washer, snap ring (outer) and sub gear onto the 1st driven gear.
3. Install the 1st driven gear, inner baulk ring, synchro cone, outer baulk ring, gear & hub assembly onto driven shaft.
|
(A) |
1st driven gear |
|
(B) |
Synchro cone |
|
(C) |
Inner baulk ring |
|
(D) |
Outer baulk ring |
NOTE:
• Take care to install the gear & hub assembly in proper direction.
• Align the baulk ring and gear & hub assembly with the key groove.
4. Install the 2nd driven gear bushing onto the 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 |
5. Install the 2nd driven gear, inner baulk ring, synchro cone and outer baulk ring, and insert them onto driven shaft.
|
(A) |
2nd driven gear |
|
(B) |
Synchro cone |
|
(C) |
Inner baulk ring |
|
(D) |
Outer baulk ring |
6. 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 |
7. Install a set of roller bearings onto the driven shaft using the 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. 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 |
9. Install the lock washer. Install the lock nut and tighten to the specified torque using the ST.
| ST 499987300 | SOCKET WRENCH (50) |
Tightening torque:
260 N·m (26.5 kgf-m, 191.8 ft-lb)
NOTE:
• 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).
10. 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 |
11. 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 |
12. Install the thrust bearing and needle bearing. Install the driven shaft assembly.
13. 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 pinion shaft |
|
(C) |
Drive pinion collar |
|
(D) |
Needle bearing (25 × 30 × 20) |
|
(E) |
Adjusting washer No. 2 (25 × 36 × 4) |
|
(F) |
Thrust bearing (25 × 37.5 × 3) |
|
(G) |
Adjusting washer No. 1 (25 × 36 × t) |
|
(H) |
Differential bevel gear sleeve |
14. Adjust the thrust bearing preload. 