Drive Pinion Shaft Assembly

MANUAL TRANSMISSION AND DIFFERENTIAL

16.Drive Pinion Shaft Assembly NOTE:

• Loosen the two bolts and adjust so that the scale
A: REMOVAL indicates 0.5 correctly when the plate end and the
1) Remove the manual transmission assembly scale end are on the same level.
from vehicle. <Ref. to 5MT-25, REMOVAL, Manual • Tighten the two bolts.
Transmission Assembly.> ST 499917500 DRIVE PINION GAUGE
2) Remove the transfer case with extension case ASSY
assembly. <Ref. to 5MT-37, REMOVAL, Transfer
Case and Extension Case Assembly.> (A)
3) Remove the transmission case. <Ref. to 5MT-
49, REMOVAL, Transmission Case.>
4) Remove the drive pinion shaft assembly.
NOTE:
Use a hammer handle, etc. to remove if too tight.
(A)
(B)
ST (B)
MT-00242

(A) Plate
(B) Scale

5) Position the ST by inserting the knock pin of ST

into the knock hole in the transmission case.
ST 499917500 DRIVE PINION GAUGE
MT-00161
ASSY
(A) Main shaft ASSY for single-range
6) Slide the drive pinion gauge scale with finger tip
and read the value at the point where it matches
(B) Drive pinion shaft ASSY
with the end face of drive pinion.
B: INSTALLATION ST 499917500 DRIVE PINION GAUGE
ASSY
1) Remove the differential assembly.
2) Alignment marks/numbers on hypoid gear set:
Use hypoid driven gear of its match number corre- ST
(A)
sponding with upper one on the drive pinion (A).
The figure (B) shows a number for shim adjust-
ment. If no number is shown, the value is zero.

(A)

MT-00243
+0
.1
(A) Adjust clearance to zero without shim.

(B) 7) The thickness of shim shall be determined by

(A) adding the value indicated on drive pinion to the
MT-00990 value indicated on the ST. (Add if the number on
drive pinion is prefixed by +, and subtract if the
(A) Match number number is prefixed by −.)
(B) Number for shim adjustment ST 499917500 DRIVE PINION GAUGE
ASSY
3) Place the drive pinion shaft assembly on the 8) Select one to three shims in the next table for the
transmission main case RH without shim and tight- value determined as described above, and take the
en the bearing mounting bolts. shim(s) which thickness is closest to the said value.
4) Inspection and adjustment of ST:

5MT-57
 Drive Pinion Shaft Assembly
MANUAL TRANSMISSION AND DIFFERENTIAL

Remove the differential bevel gear sleeve, adjust-

Drive pinion shim
ing washer No. 1, adjusting washer No. 2, thrust
Part Number Thickness mm (in)
bearing, needle bearing and drive pinion collar.
32295AA031 0.150 (0.0059)
32295AA041 0.175 (0.0069) (E)
(F)
32295AA051 0.200 (0.0079) (G)
(H)
32295AA061 0.225 (0.0089)
32295AA071 0.250 (0.0098)
32295AA081 0.275 (0.0108)
32295AA091 0.300 (0.0118)
32295AA101 0.500 (0.0197)
(A)
(B)
9) Install the differential assembly. <Ref. to 5MT- (C)
65, INSTALLATION, Front Differential Assembly.> (D) MT-00245
10) Set the transmission main shaft assembly for
single-range and drive pinion assembly in position (A) Differential bevel gear sleeve
(So there is no clearance between these two when (B) Washer No. 1 (25 × 37.5 × t)
moved all the way to the front). Inspect the suitable (C) Thrust bearing (25 × 37.5 × 3)
1st — 2nd, 3rd — 4th and 5th shifter fork so that the (D) Washer No. 2 (25 × 37.5 × 4)
coupling sleeve and reverse driven gear are posi- (E) Needle bearing (25 × 30 × 20)
tioned in the center of their synchronizing mecha- (F) Drive pinion collar
nisms. <Ref. to 5MT-62, INSPECTION, Drive (G) Needle bearing (30 × 37 × 23)
Pinion Shaft Assembly.> (H) Thrust bearing (33 × 50 × 3)
11) Install the transmission case. <Ref. to 5MT-49,
INSTALLATION, Transmission Case.> 3) Remove the roller bearing and washer using ST
12) Install the transfer case with extension case as- and press.
sembly. <Ref. to 5MT-37, INSTALLATION, Trans- NOTE:
fer Case and Extension Case Assembly.> Do not reuse the roller bearing.
13) Install the manual transmission assembly to ve-
hicle. <Ref. to 5MT-25, Manual Transmission As- ST 498077000 REMOVER
sembly.>
C: DISASSEMBLY
NOTE:
Attach a cloth to the end of driven shaft (on the fric-
tional side of thrust needle bearing) to prevent
damage during disassembly or reassembly.
1) Unlock the caulking of lock nut. Remove the lock
ST
nut using ST1, ST2 and ST3.
ST1 899884100 HOLDER MT-00246
ST2 498427100 STOPPER
ST3 899988608 SOCKET WRENCH (27) 4) Unlock the caulking of lock nut. Remove the lock
nut using ST1 and ST2.
ST1 ST1 499987300 SOCKET WRENCH (50)
ST2 899884100 HOLDER
ST2
ST2 ST1

ST3
MT-00244

2) Draw out the drive pinion from driven shaft.

MT-00247

5) Remove the 5th driven gear using ST.

5MT-58
 Drive Pinion Shaft Assembly
MANUAL TRANSMISSION AND DIFFERENTIAL

ST 499857000 5TH DRIVEN GEAR REMOV- 10) Remove the 1st driven gear, 2nd gear bushing,
ER gear and hub using ST1 and ST2. (Non-turbo mod-
el).

(A) (B) (C)

ST

MT-00248 (D)
MT-01224
6) Remove the woodruff key.
7) Remove the roller bearing and 3rd-4th driven (A) 1st driven gear
gear using ST1 and ST2.
(B) Inner baulk ring
ST1 499757002 INSTALLER
(C) Hub
ST2 899714110 REMOVER
(D) 2nd gear bushing

11) Remove the 1st driven gear, inner baulk ring,

ST1 synchro cone, outer baulk ring, 2nd gear bushing,
gear and hub using ST1 and ST2. (Turbo model)
ST2 (A)
(D)

MT-00249

8) Remove the key.

9) Remove the 2nd driven gear, inner baulk ring,
synchro cone and outer baulk ring.
(C) (B) MT-00992
(D) (A)
(A) 1st driven gear
(B) Inner baulk ring
(C) Synchro cone
(D) Outer baulk ring

NOTE:
Replace the gear and hub if necessary. Do not dis-
assemble because they must engage at a specified
(C) (B)
MT-01223 point. If they have to be disassembled, mark the
engaging point on the spline beforehand.
(A) 2nd driven gear ST1 499757002 INSTALLER
(B) Inner baulk ring
(C) Synchro cone
(D) Outer baulk ring

5MT-59
 Drive Pinion Shaft Assembly
MANUAL TRANSMISSION AND DIFFERENTIAL

ST2 899714110 REMOVER 4) Install the 1st driven gear, inner baulk ring, syn-
chro cone, outer baulk ring, gear and hub assembly
onto driven shaft. (Turbo model)

ST1 (A)
(D)

ST2

MT-00251

D: ASSEMBLY (C) (B) MT-00992

1) Install the sleeve and hub assembly by matching
alignment marks. (A) 1st driven gear
NOTE: (B) Inner baulk ring
Use the new gear and hub assembly, when replac- (C) Synchro cone
ing the gear or hub. (D) Outer baulk ring

NOTE:
(B)
(A) • Take care to install the gear and hub assembly in
proper direction.
(C) • Align the baulk ring and gear and hub assembly
with key groove.
5) Install the 2nd driven gear bushing onto driven
(D)
shaft using ST1, ST2 and a press.
NOTE:
• Do not apply pressure in excess of 10 kN (1 ton,
MT-00252
1.1 US ton, 1.0 Imp ton).
(A) 1st gear side • Attach a cloth to the end of driven shaft to pre-
(B) 2nd gear side
vent damage.
• When press-fitting, align the oil holes of shaft and
(C) Flush surface
bushing.
(D) Stepped surface
ST1 499277200 INSTALLER
2) Install the washer to 1st driven gear. ST2 499587000 INSTALLER
3) Install the 1st driven gear, 1st baulk ring, gear
and hub assembly onto driven shaft. (Non-turbo
model).
ST1
(A) (B) (C)

ST2

MT-00253

(D)
MT-01224

(A) 1st driven gear

(B) 1st baulk ring
(C) Gear and hub ASSY
(D) 2nd gear bushing

5MT-60
 Drive Pinion Shaft Assembly
MANUAL TRANSMISSION AND DIFFERENTIAL

6) Install the 2nd driven gear, inner baulk ring, syn- 9) Position the woodruff key in groove on the rear
chro cone and outer baulk ring, and insert onto driv- of driven shaft. Install the 5th driven gear onto driv-
en shaft. en shaft using ST and press.
NOTE:
(D) (A)
Do not apply pressure in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton).
ST 499277200 INSTALLER

ST
(C) (B)
MT-01223

(A) 2nd driven gear

(B) Inner baulk ring
(C) Synchro cone
MT-00257
(D) Outer baulk ring
10) Install the lock washer. Install the lock nut and
7) After installing the key on driven shaft, install the tighten to the specified torque using ST.
3rd-4th driven gear using ST and press. ST 499987300 SOCKET WRENCH (50)
NOTE: Tightening torque:
• Do not apply pressure in excess of 10 kN (1 ton, 260 N⋅m (26.5 kgf-m, 191.7 ft-lb)
1.1 US ton, 1.0 Imp ton).
• Align the groove in baulk ring with insert.
ST 499277200 INSTALLER ST

ST

MT-00258

NOTE:
MT-00255 • Stake the caulking of lock nut at two points.
• Using a spring balancer, check that starting
8) Install a set of roller bearings onto the driven
torque of roller bearing is 0.1 to 1.5 N (0.01 to 0.15
shaft using ST and press.
kgf, 0.02 to 0.33 Ibf).
NOTE:
Do not apply pressure in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton).
ST 499277200 INSTALLER

ST

MT-00259

11) Install the roller bearing onto drive pinion.

MT-00256

5MT-61
 Drive Pinion Shaft Assembly
MANUAL TRANSMISSION AND DIFFERENTIAL

NOTE: NOTE:
When installing roller bearing, note its directions Be careful because the spacer must be installed in
(front and rear) because the knock pin hole in outer proper direction.
race is offset.
(A) (B)
(A)

(C) (D) (E) (F) (G) (H)

MT-00263
(B) MT-00260
(A) Driven shaft
(A) Roller bearing (B) Drive shaft
(B) Knock pin hole (C) Drive pinion collar
(D) Needle bearing (25 × 30 × 20)
12) Install the washer using ST1, ST2 and a press.
(E) Washer No. 2 (25 × 36 × 4)
NOTE: (F) Thrust bearing (25 × 37.5 × 3)
Do not apply pressure in excess of 10 kN (1 ton, 1.1 (G) Washer No. 1 (25 × 36 × t)
US ton, 1.0 Imp ton).
(H) Differential bevel gear sleeve
ST1 499277100 BUSHING 1-2 INSTALLER
ST2 499277200 INSTALLER 15) Adjust the thrust bearing preload. <Ref. to
5MT-63, THRUST BEARING PRELOAD, AD-
JUSTMENT, Drive Pinion Shaft Assembly.>
E: INSPECTION
ST2
Disassembled parts should be washed with un-
leaded gasoline first and then inspected carefully.
ST1 1) Bearings
Replace the bearing in following cases:
(A) • When the bearing balls, outer races and inner
races are broken or rusty.
MT-00261 • When the bearing is worn.
• When the bearings fail to turn smoothly or emit
(A) Washer noise in rotation after gear oil lubrication.
• The ball bearing on the rear side of the drive pin-
13) Install the thrust bearing and needle bearing. ion shaft should be checked for smooth rotation be-
Install the driven shaft assembly. fore the drive pinion assembly is disassembled. In
this case, because a preload is working on the

MT-00262

14) 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.

5MT-62
 Drive Pinion Shaft Assembly
MANUAL TRANSMISSION AND DIFFERENTIAL

bearing, its rotation feels like it is slightly dragging Replace the insert key if deformed, excessively
unlike other bearings. worn, or defective in any way.

(A)
(A)

(B)

MT-00264 MT-00989

(A) Drive pinion shaft (A) Insert key

(B) Ball bearing
6) Oil seal
• When bearings have other defects: Replace the oil seal if the lip is deformed, hard-
2) Bushing (each gear) ened, worn or defective in any way.
Replace the bushings in following cases: 7) O-ring
• When the sliding surface is damaged or abnor- Replace the O-ring if the sealing face is deformed,
mally worn. hardened, damaged, worn, or defective in any way.
• When the inner wall is abnormally worn. F: ADJUSTMENT
3) Gears
• Replace gears with new ones if their tooth sur- 1. THRUST BEARING PRELOAD
faces are broken, damaged or excessively worn. 1) Select a suitable adjusting washer No. 1 to ad-
• Correct or replace if the cone that contacts the just dimension (H) to zero through visual check.
baulk ring is rough or damaged. Position the washer (18.3 × 30 × 4) and lock washer
• Correct or replace if the inner surface or end face (18 × 30 × 2) and install the lock nut (18 × 13.5).
is damaged.
4) Baulk ring
Replace the ring in following cases:
• When the inner surface and end face are dam-
aged.
• When the ring inner surface is abnormally or par-
tially worn.
• If the gap between the end faces of ring and the
gear splined part is excessively small, check the
clearance (A) while pressing the ring against the
cone.
Clearance (A):
0.5 — 1.0 mm (0.020 — 0.040 in)

(A)
(H)

MT-00267

2) Using the ST1, ST2 and ST3, tighten new lock

MT-00265
nut to the specified torque.
• When the contact surface of synchronizer ring in- ST1 899884100 HOLDER
sert is scratched or abnormally worn. ST2 498427100 STOPPER
5) Shifting insert key ST3 899988608 SOCKET WRENCH (27)

5MT-63
 Drive Pinion Shaft Assembly
MANUAL TRANSMISSION AND DIFFERENTIAL

Tightening torque: 5) When the specified starting cannot be obtained

120 N⋅m (12.2 kgf-m, 88.5 ft-lb) by the adjusting washer No. 2, select new adjusting
washer No. 1 and recheck starting torque.
ST1

ST2

ST3
(A)
MT-00268 (B)
MT-00270
3) After removing the ST2, measure the starting
torque using torque driver. (A) Adjusting washer No. 1
ST1 899884100 HOLDER (B) Adjusting washer No. 2
ST3 899988608 SOCKET WRENCH (27)
Starting torque: Adjusting washer No. 1
0.3 — 0.8 N⋅m (0.03 — 0.08 kgf-m, 0.2 — 0.6 ft- Part Number Thickness mm (in)
lb) 803025051 3.925 (0.1545)
803025052 3.950 (0.1555)
ST1 803025053 3.975 (0.1565)
803025054 4.000 (0.1575)
ST3 803025055 4.025 (0.1585)
803025056 4.050 (0.1594)
803025057 4.075 (0.1604)

Starting torque Dimension H Washer No. 1

Low Small Select thicker one.
MT-00269 High Large Select thinner one.

4) If the starting torque is not within the specified 6) Recheck that the starting torque is within speci-
limit, select the adjusting washer No. 2 from follow- fied range, then clinch the lock nut at four positions.
ing table, and recheck the starting torque.

(A)
(B)
MT-00270

(A) Adjusting washer No. 1

(B) Adjusting washer No. 2

Adjusting washer No. 2

Part Number Thickness mm (in)
803025059 3.850 (0.1516)
803025054 4.000 (0.1575)
803025058 4.150 (0.1634)

5MT-64