Page 817 of 2890
B3M0088A
B: ASSEMBLY
1) Assemble sleeve and hub assembly for 3rd-4th and, 5th
and high-low synchronizing.
NOTE:
Position open ends of spring 120°apart.
A: Two holes for discrimination (3rd-4th hub)
B3M0089A
B: One hole for discrimination (5th hub)
2) Install 3rd drive gear, baulk ring, and sleeve and hub
assembly for 3rd-4th needle bearing (32 x 36 x 25.7) on
transmission main shaft.
NOTE:
Align groove in baulk ring with shifting insert.
G3M0648
3) Install 4th needle bearing race1onto transmission
main shaft using ST1, ST2 and a press.
ST1 899714110 REMOVER
ST2 499877000 RACE 4-5 INSTALLER
B3M0090A
4) Install baulk ring, needle bearing (32 x 30 x 25.7), 4th
drive gear and 4th gear thrust washer to transmission main
shaft.
NOTE:
Face thrust washer in the correct direction.
a: Groove
b: 4th gear side
61
3-1SERVICE PROCEDURE
7. Main Shaft Assembly
Page 818 of 2890

G3M0650
5) Drive ball bearing1onto the rear section of transmis-
sion main shaft using ST1, ST2 and a press.
ST1 899714110 REMOVER
ST2 499877000 RACE 4-5 INSTALLER
B3M0091A
6) Using the same tools as in step 5) above, install the
following parts onto the rear section of transmission main
shaft.
5th gear thrust washer
NOTE:
Face thrust washer in the correct direction.
c: Face this surface to 5th gear side.
ST1 899714110 REMOVER
ST2 499877000 RACE 4-5 INSTALLER
5th needle bearing race
B3M0092A
7) Install the following parts to the rear section of transmis-
sion main shaft.
Needle bearing (32 x 36 x 25.7)
5th drive gear
Baulk ring
Sleeve
Aand hub assembly
Insert stopper plate
B
Lock washerC(22x38x2)
Tighten lock nuts
D(22 x 13) to the specified torque
using ST1 and ST2.
ST1 499987003 SOCKET WRENCH (35)
ST2 498937000 TRANSMISSION HOLDER
NOTE:
Align groove
Ein baulk ring with shifting insert.
Be sure to fit pawl
Fof insert stopper plate into 4 mm
(0.16 in) dia. hole in the boss section of synchronizer hub.
Secure lock nuts in two places after tightening.
Tightening torque:
118±6 N⋅m (12.0±0.6 kg-m, 86.8±4.3 ft-lb)
62
3-1SERVICE PROCEDURE
7. Main Shaft Assembly
Page 819 of 2890
8. Center Differential (AWD Model)
A: DISASSEMBLY
B3M0288A
1) Remove snap ring1(Inner-110) using flat bladed
screwdriver.
2) Remove center differential cover
2.
3) Remove snap ring
4and roller bearing3.
4) Remove viscous coupling
5.
5) Remove needle bearings
6.
6) Remove adjusting washer
7(45x62xt).
7) Remove pinion shaft
8, bevel pinions9and retainers
10.
8) Remove side gear
11.
9) Remove thrust washer
12.
G3M0662
10) Remove ball bearing13using ST.
ST 498077300 CENTER DIFFERENTIAL BEARING
REMOVER
CAUTION:
Do not reuse ball bearing.
63
3-1SERVICE PROCEDURE
8. Center Differential (AWD Model)
Page 820 of 2890

B3M0337
B: ASSEMBLY
Assembly is in the reverse order of disassembly.
Do the following:
Install thrust washer with chamfered side of inner perim-
eter facing the side gear.
Install adjusting washer with chamfered side of inner
perimeter facing the viscous coupling using ST.
ST 499547300 INSTALLER SET
B3M0095A
1) Selection of snap ring (Inner-110)
(1) After assembling, using a thickness gauge mea-
sure clearance between snap ring
1and center differ-
ential case.
Clearance:
0—0.15 mm (0—0.0059 in)
(2) If the measurement is not within the specification,
select suitable snap ring.
Snap ring (Inner-110)
Part No. Thickness mm (in)
805100061 2.10 (0.0827)
805100062 2.21 (0.0870)
805100063 2.32 (0.0913)
B3M0096A
2) Selection of adjusting washer (Backlash adjustment)
(1) After assembling, set up a ST1 and ST2 to end of
viscous coupling shaft. Move viscous coupling up and
down, and measure backlash in the axial direction.
ST1 498247001 MAGNET BASE
ST2 498247100 DIAL GAUGE
Backlash:
0.62—0.86 mm (0.0244—0.0339 in)
(2) If the measurement is not within the specification,
select suitable washer.
Adjusting washer (45 x 62 x t)
Part No. Thickness mm (in)
803045041 1.60 (0.0630)
803045042 1.80 (0.0709)
803045043 2.00 (0.0787)
803045044 2.20 (0.0866)
803045045 2.40 (0.0945)
64
3-1SERVICE PROCEDURE
8. Center Differential (AWD Model)
Page 821 of 2890
G3M0666
9. Front Differential
A: DISASSEMBLY
1) Remove right and left snap rings1from differential,
and then remove two axle drive shafts
2.
NOTE:
During reassembly, reinstall each axle drive shaft in the
same place from which it was removed.
2) Loosen twelve bolts
3and remove hypoid drive gear
4.
G3M0667
3) Drive out straight pin5from differential assembly
toward hypoid driven gear.
ST 899904100 REMOVER
G3M0666
4) Pull out pinion shaft6, and remove differential bevel
pinion
7and gear8and washer9.
65
3-1SERVICE PROCEDURE
9. Front Differential
Page 822 of 2890
G3M0668
5) Remove roller bearing using ST.
ST 399527700 PULLER SET
B3M0099A
B: ASSEMBLY
1) Install bevel gear and bevel pinion together with
washers, and insert pinion shaft
1.
NOTE:
Face the chamfered side of washer toward gear.
G3M0670
2) Measure backlash between bevel gear and pinion. If it
is not within specifications, install a suitable washer to
adjust it.
Standard backlash:
0.13—0.18 mm (0.0051—0.0071 in)
ST1 498247001 MAGNET BASE
ST2 498247100 DIAL GAUGE
NOTE:
Be sure the pinion gear tooth contacts adjacent gear teeth
during measurement.
Washer (38.1 x 50 x t)
Part No. Thickness mm (in)
803038021 0.925—0.950 (0.0364—0.0374)
803038022 0.975—1.000 (0.0384—0.0394)
803038023 1.025—1.050 (0.0404—0.0413)
66
3-1SERVICE PROCEDURE
9. Front Differential
Page 823 of 2890
G3M0666
3) Align pinion shaft and differential case at their holes,
and drive straight pin
5into holes from the hypoid driven
gear side, using ST.
ST 899904100 REMOVER
NOTE:
Lock straight pin after installing.
G3M0671
4) Install roller bearing (40 x 80 x 19.75) to differential
case.
NOTE:
Be careful because roller bearing outer races are used as
a set.
ST1 499277100 BUSH 1-2 INSTALLER
ST2 398497701 ADAPTER
G3M0666
5) Install hypoid driven gear4to differential case10using
twelve bolts
3.
Tightening torque:
62±5 N⋅m (6.3±0.5 kg-m, 45.6±3.6 ft-lb)
67
3-1SERVICE PROCEDURE
9. Front Differential
Page 824 of 2890
B3M0100
6) Position drive axle shaft in differential case and hold it
with outer snap ring (28). Using a thickness gauge, mea-
sure clearance between the shaft and case is within speci-
fications.
Clearance:
0—0.2 mm (0—0.008 in)
If it is not within specifications, replace snap ring with a
suitable one.
Snap ring (Outer-28)
Part No. Thickness mm (in)
805028011 1.05 (0.0413)
805028012 1.20 (0.0472)
68
3-1SERVICE PROCEDURE
9. Front Differential