Page 681 of 3342

G3M0573
12) Selecting of main shaft rear plate
Using ST, measure the amount A of ball bearing protrusion
from transmission main case surface and select the proper
plate in the following table:
ST 498147000 DEPTH GAUGE
Dimension“A”
mm (in)Part No. Mark
4.00—4.13
(0.1575—0.1626)32294AA041 1
3.87—3.99
(0.1524—0.1571)32294AA051 2
NOTE:
Before measuring, tap the end of main shaft with a plastic
hammer lightly in order to make the clearance zero
between the main case surface and the moving flange of
bearing.
B3M0336D
13) Install clutch release lever1and operating cylinder
(hydraulic application type)
2.
[W3C2], [W5A0].>
G3M0595
5. Drive Pinion Assembly (AWD Model)
A: DISASSEMBLY
1. DRIVE PINION SHAFT
1) Straighten lock nut at staked portion. Remove the lock
nut using ST1, ST2 and ST3.
ST1 899884100 HOLDER
ST2 498427100 STOPPER
ST3 899988608 SOCKET WRENCH
G3M0606
2) Withdraw drive pinion from driven shaft.
Remove differential bevel gear sleeve
1, adjusting washer
No. 1
2(25 x 37.5 x t), adjusting washer No. 23(25 x
37.5 x 4), thrust bearing
4(25 x 37.5 x 3), needle bearing
5(25 x 30 x 20), drive pinion collar6, needle bearing7
(30 x 37 x 23) and thrust bearing8(33x50x3).
49
3-1SERVICE PROCEDURE
5. Drive Pinion Assembly (AWD Model)
Page 682 of 3342

G3M0573
12) Selecting of main shaft rear plate
Using ST, measure the amount A of ball bearing protrusion
from transmission main case surface and select the proper
plate in the following table:
ST 498147000 DEPTH GAUGE
Dimension“A”
mm (in)Part No. Mark
4.00—4.13
(0.1575—0.1626)32294AA041 1
3.87—3.99
(0.1524—0.1571)32294AA051 2
NOTE:
Before measuring, tap the end of main shaft with a plastic
hammer lightly in order to make the clearance zero
between the main case surface and the moving flange of
bearing.
B3M0336D
13) Install clutch release lever1and operating cylinder
(hydraulic application type)
2.
[W3C2], [W5A0].>
G3M0595
5. Drive Pinion Assembly (AWD Model)
A: DISASSEMBLY
1. DRIVE PINION SHAFT
1) Straighten lock nut at staked portion. Remove the lock
nut using ST1, ST2 and ST3.
ST1 899884100 HOLDER
ST2 498427100 STOPPER
ST3 899988608 SOCKET WRENCH
G3M0606
2) Withdraw drive pinion from driven shaft.
Remove differential bevel gear sleeve
1, adjusting washer
No. 1
2(25 x 37.5 x t), adjusting washer No. 23(25 x
37.5 x 4), thrust bearing
4(25 x 37.5 x 3), needle bearing
5(25 x 30 x 20), drive pinion collar6, needle bearing7
(30 x 37 x 23) and thrust bearing8(33x50x3).
49
3-1SERVICE PROCEDURE
5. Drive Pinion Assembly (AWD Model)
Page 683 of 3342

G3M0607
3) Remove roller bearing and washer (33 x 50 x 5) using
ST and press.
ST 498077000 REMOVER
CAUTION:
Do not reuse roller bearing.
G3M0608
2. DRIVEN GEAR ASSEMBLY (2200 cc MODEL)
CAUTION:
Attach a cloth to the end of driven shaft (on the fric-
tional side of thrust needle bearing) during disassem-
bly or reassembly to prevent damage.
1) Straighten lock nut at staked portion. Remove the lock
nut using ST1 and ST2.
ST1 499987300 SOCKET WRENCH (50)
ST2 899884100 HOLDER
G3M0609
2) Remove 5th driven gear using ST.
ST 499857000 5TH DRIVEN GEAR REMOVER
G3M0610
3) Remove woodruff key.
4) Remove roller bearing (42 x 74 x 40), 3rd and 4th driven
gear using ST1 and ST2.
ST1 499757002 SNAP RING PRESS
ST2 899714110 REMOVER
G3M0611
5) Remove the key.
6) Remove 2nd driven gear assembly.
7) Remove 1st driven gear, 2nd gear bushing, gear and
hub using ST1 and ST2.
Replace gear and hub if necessary. Do not attempt to dis-
assemble if at all possible because they must engage at a
specified point. If they have to be disassembled, mark the
engaging point beforehand.
ST1 499757002 SNAP RING PRESS
ST2 899714110 REMOVER
50
3-1SERVICE PROCEDURE
5. Drive Pinion Assembly (AWD Model)
Page 684 of 3342
8) Remove sub gears for 1st and 2nd driven gear.
G3M0608
3. DRIVEN GEAR ASSEMBLY (2500 cc MODEL)
CAUTION:
Attach a cloth to the end of driven shaft (on the fric-
tional side of thrust needle bearing) during disassem-
bly or reassembly to prevent damage.
1) Straighten lock nut at staked portion. Remove the lock
nut using ST1 and ST2.
ST1 499987300 SOCKET WRENCH (50)
ST2 899884100 HOLDER
G3M0609
2) Remove 5th driven gear using ST.
ST 499857000 5TH DRIVEN GEAR REMOVER
G3M0610
3) Remove woodruff key.
4) Remove roller bearing (42 x 74 x 40), 3rd-4th driven
gear using ST1 and ST2.
ST1 499757002 SNAP RING PRESS
ST2 899714110 REMOVER
B3M0426A
5) Remove the key.
6) Remove 2nd driven gear
1, inner baulk ring2, synchro
cone
3and outer baulk ring4.
51
3-1SERVICE PROCEDURE
5. Drive Pinion Assembly (AWD Model)
Page 685 of 3342
G3M0611
7) Remove 1st driven gear, 2nd gear bushing, gear and
hub using ST1 and ST2.
NOTE:
Replace gear and hub if necessary. Do not attempt to dis-
assemble if at all possible because they must engage at a
specified point. If they have to be disassembled, mark the
engaging point beforehand.
ST1 499757002 SNAP RING PRESS
ST2 899714110 REMOVER
8) Remove sub gear for 1st driven gear.
B3M0077A
B: ASSEMBLY
1. GEAR AND HUB ASSEMBLY (2200 cc MODEL)
NOTE:
Position open ends of springs 120°apart.
A: 1st gear side
B: 2nd gear side
C: Flush surface
D: Stepped surface
B3M0431A
2. GEAR AND HUB ASSEMBLY (2500 cc MODEL)
Assemble gear and hub assembly.
NOTE:
Use new gear and hub assembly, if gear or hub have
been replaced.
Be sure the insert keys are correctly located in the insert
key grooves
1inside the reverse driven gear2.
B3M0077A
A: 1st gear side
B: 2nd gear side
C: Flush surface
D: Stepped surface
52
3-1SERVICE PROCEDURE
5. Drive Pinion Assembly (AWD Model)
Page 686 of 3342

G3M0613
3. DRIVEN GEAR ASSEMBLY (2200 cc MODEL)
Assemble a driven shaft and 1st driven gear that select for
adjustment the proper radial clearance.
Driven shaft 1st driven gear
Part No. Diameter A mm (in) Part No.
32229AA15049.959—49.966
(1.9669—1.9672)32231AA290
32229AA14049.967—49.975
(1.9672—1.9675)32231AA280
B3M0078A
1) Install 1st driven gear, 1st-2nd baulk ring and gear and
hub assembly onto driven shaft.
NOTE:
Take care to install gear hub in proper direction.
2) Install 2nd driven gear bushing onto driven shaft using
ST1, ST2 and press.
ST1 499277200 INSTALLER
ST2 499587000 INSTALLER
CAUTION:
Attach a cloth
1to the end of driven shaft to prevent
damage.
G3M0615
3) Install 2nd driven gear, 1st-2nd baulk ring and insert
onto driven shaft. After installing key on driven shaft, install
3rd-4th driven gear using ST and press.
ST 499277200 INSTALLER
Align groove in baulk ring with insert.
G3M0616
4) Install a set of roller bearings (42 x 74 x 40) onto the
driven shaft using ST and press.
ST 499277200 INSTALLER
53
3-1SERVICE PROCEDURE
5. Drive Pinion Assembly (AWD Model)
Page 687 of 3342
G3M0617
5) Position woodruff key in groove on the rear of driven
shaft. Install 5th driven gear onto drive shaft using ST and
press.
ST 499277200 INSTALLER
G3M0618
6) Install lock washer (42 x 53 x 2). Install lock nut (42 x
13) and tighten to the specified torque using ST.
ST 499987300 SOCKET WRENCH (50)
Tightening torque:
265±10 N⋅m (27±1 kg-m, 195±7 ft-lb)
B3M0079A
NOTE:
Stake lock nut at two points.
Using spring balancer, check that starting torque of roller
bearing
2is 0.1 to 1.5 N⋅m (1 to 15 kg-cm, 0.9 to 13.0 in-
lb).
G3M0613
4. DRIVEN GEAR ASSEMBLY (2500 cc MODEL)
Assemble a driven shaft and 1st driven gear that select for
adjustment the proper radial clearance.
Driven shaft 1st driven gear
Part No. Diameter A mm (in) Part No.
32229AA15049.959—49.966
(1.9669—1.9672)32231AA290
32229AA14049.967—49.975
(1.9672—1.9675)32231AA280
54
3-1SERVICE PROCEDURE
5. Drive Pinion Assembly (AWD Model)
Page 688 of 3342
B3M0078A
1) Install sub gear to 1st driven gear.
2) Install 1st driven gear, 1st baulk ring, gear and hub
assembly onto driven shaft.
NOTE:
Take care to install gear hub in proper direction.
3) Install 2nd driven gear bushing onto driven shaft using
ST1, ST2 and press.
ST1 499277200 INSTALLER
ST2 499587000 INSTALLER
CAUTION:
Attach a cloth
1to the end of driven shaft to prevent
damage.
NOTE:
When press fitting, align oil holes of shaft and bush.
B3M0426A
4) Install 2nd driven gear1, inner baulk ring2, synchro
cone
3, outer baulk ring4and insert onto driven shaft.
G3M0615
5) After installing key on driven shaft, install 3rd-4th driven
gear using ST and press.
ST 499277200 INSTALLER
NOTE:
Align groove in baulk ring with insert.
G3M0616
6) Install a set of roller bearings (42 x 74 x 40) onto the
driven shaft using ST and press.
ST 499277200 INSTALLER
55
3-1SERVICE PROCEDURE
5. Drive Pinion Assembly (AWD Model)