Page 2057 of 3833
MAINSHAFT AND GEARS
MT-81
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11. Select suitable adjusting shim so that dimension “C1” satisfies
standard value below, and install it onto mainshaft.
Adjusting Shim
CAUTION:
Only one adjusting shim can be selected.
12. Install 4th main gear.
CAUTION:
Be careful with orientation of 4th main gear.
13. Install 5th main gear.
CAUTION:
Be careful with orientation of 5th main gear.
14. Install 5th-6th mainshaft spacer. Standard for dimension C1
: 173.85 - 173.95 mm (6.844 - 6.848 in)
SCIA0944E
Thickness Part number Thickness Part number
0.52 mm (0.0205 in)
0.60 mm (0.0236 in)
0.68 mm (0.0268 in)
0.76 mm (0.0299 in)32238 8H500
32238 8H501
32238 8H502
32238 8H5030.84 mm (0.0331 in)
0.92 mm (0.0362 in)
1.00 mm (0.0394 in)
1.08 mm (0.0425 in)32238 8H504
32238 8H505
32238 8H506
32238 8H507
SCIA0945E
SCIA0946E
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MT-82
MAINSHAFT AND GEARS
15. Install 6th main gear.
16. Select 6th main adjusting shim and then install it onto mainshaft.
●Calculate thickness “S” of 6th main adjusting shim by proce-
dure below so that end play dimension between 6th main
gear and mainshaft rear bearing becomes the dimension
shown below.
Adjusting Shim
CAUTION:
Only one adjusting shim can be selected.
a. Using height gauge, measure dimension “S1 ” and “S2 ”.
b. Install selected 6th main adjusting shim to mainshaft.
17. Install mainshaft rear bearing.
SCIA0977E
End play: 0 - 0.1 mm (0 - 0.004 in)
Dimension“S” = (S
1 - S2 ) + End play
S: Thickness of adjusting shim
S
1 : Dimension from mainshaft standard face to
mainshaft rear bearing press-fit end face
S
2 : Dimension from mainshaft standard face to
6th main gear end face
SCIA0995E
Thickness Part number Thickness Part number
0.88 mm (0.0346 in)
0.96 mm (0.0378 in)
1.04 mm (0.0409 in)
1.12 mm (0.0441 in)32237 8H560
32237 8H561
32237 8H562
32237 8H5631.20 mm (0.0472 in)
1.28 mm (0.0504 in)
1.36 mm (0.0535 in)32237 8H564
32237 8H565
32237 8H566
SCIA0978E
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MAINSHAFT AND GEARS
MT-83
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18. Install C-ring onto mainshaft, and check that end play of main-
shaft rear bearing satisfies standard value.
●If measurement is outside the standard range, reselect C-ring.
C-ring
19. Fit C-ring holder, and install snap ring.
20. Check end play of 1st and 2nd main gears.End play standard value : 0 - 0.06 mm (0 - 0.0024 in)
SCIA0979E
Thickness Part number Thickness Part number
2.535 mm (0.0998 in)
2.565 mm (0.1010 in)
2.595 mm (0.1022 in)
2.625 mm (0.1033 in)
2.655 mm (0.1045 in)
2.685 mm (0.1057 in)
2.715 mm (0.1069 in)
2.745 mm (0.1081 in)
2.775 mm (0.1093 in)
2.805 mm (0.1104 in)32348 8H800
32348 8H801
32348 8H802
32348 8H803
32348 8H804
32348 8H805
32348 8H806
32348 8H807
32348 8H808
32348 8H8092.835 mm (0.1116 in)
2.865 mm (0.1128 in)
2.895 mm (0.1140 in)
2.925 mm (0.1152 in)
2.955 mm (0.1163 in)
2.985 mm (0.1175 in)
3.015 mm (0.1187 in)
3.045 mm (0.1199 in)
3.075 mm (0.1211 in)32348 8H810
32348 8H811
32348 8H812
32348 8H813
32348 8H814
32348 8H815
32348 8H816
32348 8H817
32348 8H818
SCIA0974E
End play standard value
1st gear : 0.20 - 0.30 mm (0.0079 - 0.0118 in)
2nd gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)
SCIA0973E
Page 2060 of 3833

MT-84
REVERSE IDLER SHAFT AND GEARS
REVERSE IDLER SHAFT AND GEARS
PFP:32281
Assembly and Disassembly (RS5F51A)ECS008C8
DISASSEMBLY
1. Remove reverse idler gear adjusting shim.
2. Remove reverse idler gear (rear), reverse coupling sleeve and insert spring simultaneously.
3. Remove reverse idler gear needle bearing.
4. Remove thrust needle bearing.
5. Remove reverse baulk ring.
6. Remove reverse idler gear (front).
7. Remove reverse idler gear needle bearing.
8. Remove thrust needle bearing.
9. Pull off locking pin from reverse idler shaft.
INSPECTION AFTER DISASSEMBLY
Reverse Idler Shaft and Gears
Check items below. If necessary, replace them with new ones.
●Damage, peeling, dent, uneven wear, bending, and other non-
standard conditions of the shaft.
●Excessive wear, damage, peeling, and other non-standard con-
ditions of the gears.
Synchronizer
Check items below. If necessary, replace them with new ones.
●Damage and unusual wear on contact surfaces of coupling
sleeve, synchronizer hub, and insert spring.
●Coupling sleeve and synchronizer hub must move smoothly.
●If any crack, damage, or excessive wear is found on cam face of
baulk ring or working face of insert, replace it.
SCIA0953J
SMT637A
SMT867D
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REVERSE IDLER SHAFT AND GEARS
MT-85
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Baulk ring clearance
●Press baulk ring against cone, and measure clearance between
baulk ring and cone. If measurement is below limit, replace it
with a new one.
Bearing
Check items below. If necessary, replace them with new ones.
●Damage and rough rotation of bearing.
ASSEMBLY
Paying attention to following work, assemble in reverse order of disassembly.
CAUTION:
●Be careful with orientation of insert spring.
Assembly and Disassembly (RS6F51A)ECS008C9
DISASSEMBLY
1. Remove reverse idler gear adjusting shim.
2. Remove reverse idler gear (rear), reverse coupling sleeve and insert spring simultaneously.
3. Remove reverse idler gear needle bearing.
4. Remove thrust needle bearing.
5. Remove reverse baulk ring.
6. Remove reverse idler gear (front).
7. Remove reverse idler gear needle bearing.
8. Remove thrust needle bearing.
9. Pull off locking pin from reverse idler shaft.
INSPECTION AFTER DISASSEMBLY
Reverse Idler Shaft and Gears
Check items below. If necessary, replace them with new ones.
●Damage, peeling, dent, uneven wear, bending, and other non-
standard conditions of the shaft.
●Excessive wear, damage, peeling, and other non-standard con-
ditions of the gears.Clearance
Standard : 0.95 - 1.4 mm (0.0374 - 0.0551 in)
Limit value : 0.7 mm (0.0276 in)
SMT140
SCIA0954E
SCIA0953J
Page 2062 of 3833
MT-86
REVERSE IDLER SHAFT AND GEARS
Synchronizer
Check items below. If necessary, replace them with new ones.
●Damage and unusual wear on contact surfaces of coupling
sleeve, synchronizer hub, and insert spring.
●Coupling sleeve and synchronizer hub must move smoothly.
●If any crack, damage, or excessive wear is found on cam face of
baulk ring or working face of insert, replace it.
Baulk ring clearance
●Press baulk ring against cone, and measure clearance between
baulk ring and cone. If measurement is below limit, replace it
with a new one.
Bearing
Check items below. If necessary, replace them with new ones.
●Damage and rough rotation of bearing.
ASSEMBLY
Paying attention to following work, assemble in reverse order of disassembly.
CAUTION:
●Be careful with orientation of insert spring.
SMT637A
SMT867D
Clearance
Standard : 0.95 - 1.4 mm (0.0374 - 0.0551 in)
Limit value : 0.7 mm (0.0276 in)
SMT140
SCIA0954E
Page 2063 of 3833

FINAL DRIVE
MT-87
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FINAL DRIVEPFP:38411
Assembly and Disassembly (RS5F51A)ECS008CA
PRE-INSPECTION
●Check the clearance between side gear and differential case as
follows.
1. Clean final drive assembly sufficiently to prevent side gear thrust
washer, differential case, side gear, and other parts from sticking
by gear oil.
2. Upright the differential case so that the side gear to be measured faces upward.
3. Place final drive adapter and dial indicator onto side gear. Move
side gear up and down, and measure the clearance.
CAUTION:
There should be no resistance and gears should rotate
freely.
4. If not within specification, adjust the clearance by changing
thrust washer thickness.
5. Turn differential case upside down, and measure the clearance
between side gear and differential case on the other side in the
same way.
DISASSEMBLY
1. Remove mounting bolts.Then, separate the final gear from differential case.
2. Using a drift and puller, remove differential side bearing (clutch
housing side).
3. Using a drift and puller, remove differential side bearing (tran-
saxle case side).
SCIA1020E
Clearance between side gear and differential case
: 0.1 - 0.2 mm (0.004 - 0.008 in)
SMT611A
SCIA0906E
SCIA0907E
Page 2064 of 3833
MT-88
FINAL DRIVE
4. Using a pin punch, pull out lock pin and pinion mate shaft.
5. Rotate pinion mate gears, and remove pinion mate gears, pinion
mate thrust washers, side gears, and side gear thrust washers
from differential case.
INSPECTION AFTER DISASSEMBLY
Gear, Washer, Shaft and Case
●Check side gears, side gear thrust washers, pinion mate shaft,
pinion mate gears, pinion mate thrust washers and differential
case. If necessary, replace with a new one.
Bearing
●Check for bearing damage and rough rotation. If necessary,
replace with a new one.
CAUTION:
When replacing tapered roller bearing, replace outer and inner
races as a set.
ASSEMBLY
1. Apply gear oil to sliding area of differential case, each gear, and thrust washer.
2. Install side gear thrust washers and side gears into differential
case.
3. While rotating pinion mate thrust washers and pinion mate
gears, aligning them diagonally, install them into differential
case.
SCIA0908E
MTK0135D
SPD715
SMT839