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    Msa5t0124a27668 PDF

    Uploaded by

    Jeff Pascoe
    This document provides instructions for disassembling and assembling the main shaft assembly of an automatic transmission. It involves removing parts like the oil seal, lock nut, gears, sleeves, bearings and installing replacement or new parts in the reverse order. Special tools are required for pressing parts like bearings and installing races. Tolerances and alignment of parts is important, and replacing worn parts like bearings is specified.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Msa5t0124a27668 PDF

    Uploaded by

    Jeff Pascoe
    25 views5 pages
    This document provides instructions for disassembling and assembling the main shaft assembly of an automatic transmission. It involves removing parts like the oil seal, lock nut, gears, sleeves, bearings and installing replacement or new parts in the reverse order. Special tools are required for pressing parts like bearings and installing races. Tolerances and alignment of parts is important, and replacing worn parts like bearings is specified.

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    MSA5T0124A27668.pdf

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    This document provides instructions for disassembling and assembling the main shaft assembly of an automatic transmission. It involves removing parts like the oil seal, lock nut, gears, sleeves, bearings and installing replacement or new parts in the reverse order. Special tools are required for pressing parts like bearings and installing races. Tolerances and alignment of parts is important, and replacing worn parts like bearings is specified.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    25 views5 pages

    Msa5t0124a27668 PDF

    Uploaded by

    Jeff Pascoe
    This document provides instructions for disassembling and assembling the main shaft assembly of an automatic transmission. It involves removing parts like the oil seal, lock nut, gears, sleeves, bearings and installing replacement or new parts in the reverse order. Special tools are required for pressing parts like bearings and installing races. Tolerances and alignment of parts is important, and replacing worn parts like bearings is specified.

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    © All Rights Reserved
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    You are on page 1of 5

    3-1 [W4A0] SERVICE PROCEDURE

    4. Main Shaft Assembly

    5) If specified starting torque range cannot be 4. Main Shaft Assembly


    obtained when a No. 1 adjusting washer is used,
    then select a suitable No. 2 adjusting washer from A: DISASSEMBLY
    those listed in the following table. Repeat steps 1)
    1) Put vinyl tape around main shaft splines to pro-
    through 4) to adjust starting torque.
    tect oil seal from damage. Then pull out oil seal
    and needle bearing by hand.
    2) Remove lock nut from transmission main shaft
    assembly.
    NOTE:
    Remove caulking before taking off lock nut.
    ST1 498937000 TRANSMISSION HOLDER
    ST2 499987003 SOCKET WRENCH (35)

    B3M0536I

    (A) Adjusting washer No. 1


    (B) Adjusting washer No. 2

    Starting torque Dimension H Washer No. 2


    Low Small Select thicker one.
    High Large Select thinner one.

    Adjusting washer No. 2 B3M0439A


    Part No. Thickness mm (in)
    3) Remove 5th-Rev sleeve and hub assembly,
    803025059 3.850 (0.1516)
    baulk ring, 5th drive gear and needle bearing (32
    803025054 4.000 (0.1575) × 36 × 25.7).
    803025058 4.150 (0.1634)

    6) Recheck that starting torque is within specified


    range, then clinch lock nut at four positions.

    B3M0437B

    (A) 5th-Rev sleeve and hub ASSY


    (B) Baulk ring
    (C) 5th drive gear

    34
    SERVICE PROCEDURE [W4A0] 3-1
    4. Main Shaft Assembly

    4) Remove snap ring and synchro cone stopper 6) Using ST1 and ST2, remove the rest of parts.
    from 5th-Rev sleeve and hub assembly. NOTE:
    Replace sleeve and hub with new ones. Do not
    attempt to disassemble because they must engage
    at a specified point. If they should be
    disassembled, marking engagement point on
    splines beforehand.
    ST1 899864100 REMOVER
    ST2 899714110 REMOVER

    B3M0435B

    (A) Synchro cone stopper


    (B) Snap ring

    5) Using ST1, ST2 and a press, remove ball


    bearing, synchro cone and baulk ring (Rev).
    NOTE:
    I Replace sleeve and hub with new ones. Do not
    attempt to disassemble because they must engage
    at a specified point. If they should be
    disassembled, mark engagement point on splines
    beforehand.
    I Do not reuse ball bearing.
    ST1 499757002 SNAP RING PRESS
    ST2 498077400 SYNCHRO CONE
    REMOVER

    B3M0835A

    B3M1365A

    (A) Ball bearing


    (B) Synchro cone
    (C) Baulk ring

    35
    3-1 [W4B0] SERVICE PROCEDURE
    4. Main Shaft Assembly

    B: ASSEMBLY 3) Install 4th needle bearing race onto transmis-


    sion main shaft using ST1, ST2 and a press.
    1) Assemble sleeve and hub assembly for 3rd-4th
    and, 5th synchronizing. CAUTION:
    Do not apply pressure in excess of 10 kN (1 ton,
    NOTE: 1.1 US ton, 1.0 Imp ton).
    Position open ends of spring 120° apart.
    ST1 899714110 REMOVER
    ST2 499877000 RACE 4-5 INSTALLER

    B3M0543D

    (A) 4th needle bearing race

    4) Install baulk ring, needle bearing (32 × 30 ×


    25.7), 4th drive gear and 4th gear thrust washer to
    transmission main shaft.
    NOTE:
    Align baulk ring and gear & hub assembly with key
    groove.
    B3M1366A

    2) Install 3rd drive gear, outer baulk ring, synchro


    cone, inner baulk ring, sleeve and hub assembly
    for 3rd needle bearing on transmission main shaft.
    NOTE:
    Align groove in baulk ring with shifting insert.

    S3M0045A

    (A) Groove
    (B) 4th gear side

    B3M0837A

    (A) 3rd needle bearing (32 × 36 × 25.7)


    (B) 3rd drive gear
    (C) Inner baulk ring
    (D) Synchro cone
    (E) Outer baulk ring
    (F) Sleeve and hub ASSY

    36
    SERVICE PROCEDURE [W4B0] 3-1
    4. Main Shaft Assembly

    5) Drive ball bearing onto the rear section of trans- 7) Install bearing onto synchro cone.
    mission main shaft using ST1, ST2 and a press. NOTE:
    CAUTION: Align baulk ring and gear & hub assembly with key
    Do not apply pressure in excess of 10 kN (1 ton, groove.
    1.1 US ton, 1.0 Imp ton). 8) Install baulk ring and synchro cone onto 5th-
    ST1 899714110 REMOVER Rev sleeve and hub assembly using ST and a
    ST2 499877000 RACE 4-5 INSTALLER press.
    CAUTION:
    Do not apply pressure in excess of 10 kN (1 ton,
    1.1 US ton, 1.0 Imp ton).
    NOTE:
    I Use new ball bearing.
    I After press fitting, make sure synchro cone
    rotates freely.
    ST 499757002 SNAP RING PRESS

    B3M0553E

    (A) Ball bearing

    6) Using ST1 and ST2, install the 5th gear thrust


    washer and 5th needle bearing race onto the rear
    section of transmission main shaft.
    CAUTION:
    Do not apply pressure in excess of 10 kN (1 ton,
    1.1 US ton, 1.0 Imp ton).
    B3M1370A
    NOTE:
    Face thrust washer in the correct direction. (A) Baulk ring
    (B) Synchro cone
    ST1 899714110 REMOVER (C) Ball bearing
    ST2 499877000 RACE 4-5 INSTALLER
    9) Install synchro cone stopper and snap ring to
    5th-Rev sleeve and hub assembly.

    B3M0091D

    (A) Face this surface to 5th gear side. B3M0435B

    (A) Synchro cone stopper


    (B) Snap ring

    37
    3-1 [W5A0] SERVICE PROCEDURE
    5. Transfer Case and Extension

    10) Install the rest parts to the rear section of 5. Transfer Case and Extension
    transmission main shaft.
    NOTE: A: REMOVAL
    Align groove in baulk ring with shifting insert. 1) Remove back-up light switch and neutral
    ST1 499987003 SOCKET WRENCH switch.
    ST2 498937000 TRANSMISSION HOLDER

    B3M1372B
    B3M1371A
    (A) Neutral switch
    (A) Needle bearing (32 × 36 × 25.7) (B) Back-up light switch
    (B) 5th drive gear
    (C) Baulk ring 2) Remove transfer case with extension assembly.
    (D) 5th-Rev sleeve and hub ASSY
    (E) Lock washer (22 × 38 × 2)
    (F) Lock nuts (22 × 13)

    11) Tighten lock nuts to the specified torque using


    ST1 and ST2.
    NOTE:
    Secure lock nuts in two places after tightening.
    ST1 499987000 SOCKET WRENCH
    ST2 498937000 TRANSMISSION HOLDER
    B3M1373
    Tightening torque:
    118±6 N·m (12.0±0.6 kg-m, 86.8±4.3 ft-lb) 3) Remove shifter arm.

    B: DISASSEMBLY
    1. SEPARATION OF TRANSFER CASE
    AND EXTENSION ASSEMBLY
    1) Separate transfer case and extension assem-
    bly.

    B3M1374B

    (A) Extension case ASSY

    38

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