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MAINSHAFT AND GEARS
MT-81
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15. Install 6th main gear.
16. Adjustment between 6th main gear and 6th main adjusting shim.
lCalculate thickness “Q” 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 “Q1”and“Q2”.
b. Install selected 6th main adjusting shim to mainshaft.
17. Install mainshaft rear bearing.
SCIA0977E
Endplay :0-0.1mm(0-0.004in)
Dimension“Q” = (Q
1-Q2)+Endplay
Q : Thickness of adjusting shim
Q
1: Dimension from mainshaft reference face to
mainshaft rear bearing press-fit end face
Q
2: Dimension from mainshaft reference face to
6th main gear end face
SCIA0995E
Thickness Part number Thickness Part number
0.88mm (0.0346 in)
0.96mm (0.0378 in)
1.04mm (0.0409 in)
1.12mm (0.0441 in)32237 8H560
32237 8H561
32237 8H562
32237 8H5631.20mm (0.0472 in)
1.28mm (0.0504 in)
1.36mm (0.0535 in)32237 8H564
32237 8H565
32237 8H566
SCIA0978E
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MT-82
MAINSHAFT AND GEARS
18. Install C-ring onto mainshaft, and check that end play of main-
shaft rear bearing satisfies standard value.
lIf 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
2.535mm (0.0866 in)
2.565mm (0.1010 in)
2.595mm (0.1022 in)
2.625mm (0.1033 in)
2.655mm (0.1045 in)
2.685mm (0.1057 in)
2.715mm (0.1069 in)
2.745mm (0.1081 in)
2.775mm (0.1093 in)
2.805mm (0.1104 in)32348 8H800
32348 8H801
32348 8H802
32348 8H803
32348 8H804
32348 8H805
32348 8H806
32348 8H807
32348 8H808
32348 8H8092.835mm (0.1116 in)
2.865mm (0.1128 in)
2.895mm (0.1140 in)
2.925mm (0.1152 in)
2.955mm (0.1163 in)
2.985mm (0.1175 in)
3.015mm (0.1187 in)
3.045mm (0.1199 in)
3.075mm (0.1211 in)32348 8H810
32348 8H811
32348 8H812
32348 8H813
32348 8H814
32348 8H815
32348 8H816
32348 8H817
32348 8H818
SCIA0974E
Endplaystandardvalue
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 2619 of 3066

REVERSE IDLER SHAFT AND GEARS
MT-83
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REVERSE IDLER SHAFT AND GEARSPFP:32281
Assembly and Disassembly (RS5F51A)ECS004UQ
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.
lDamage, peeling, dent, uneven wear, bending, and other non-
standard conditions of the shaft.
lExcessive wear, damage, peeling, and other non-standard con-
ditions of the gears.
Synchronizer
Check items below. If necessary, replace them with new ones.
lDamage and unusual wear on contact surfaces of coupling
sleeve, synchronizer hub, and insert spring.
lCoupling sleeve and synchronizer hub must move smoothly.
lIf any crack, damage, or excessive wear is found on cam face of
baulk ring or working face of insert, replace it.
Baulk ring clearance
SCIA0953E
SMT637A
SMT867D
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MT-84
REVERSE IDLER SHAFT AND GEARS
lPress 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.
lDamage and rough rotation of bearing.
ASSEMBLY
Paying attention to following work, assemble in reverse order of disassembly.
CAUTION:
lBe careful with orientation of insert spring.
Assembly and Disassembly (RS6F51A)ECS004UV
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.
lDamage, peeling, dent, uneven wear, bending, and other non-
standard conditions of the shaft.
lExcessive wear, damage, peeling, and other non-standard con-
ditions of the gears.Clearance
Standard : 0.95 - 1.4 mm (0.0374 - 0.055 in)
Limit value : 0.7 mm (0.028 in)
SMT140
SCIA0954E
SCIA0953E
Page 2621 of 3066
REVERSE IDLER SHAFT AND GEARS
MT-85
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Synchronizer
Check items below. If necessary, replace them with new ones.
lDamage and unusual wear on contact surfaces of coupling
sleeve, synchronizer hub, and insert spring.
lCoupling sleeve and synchronizer hub must move smoothly.
lIf any crack, damage, or excessive wear is found on cam face of
baulk ring or working face of insert, replace it.
Baulk ring clearance
lPress 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.
lDamage and rough rotation of bearing.
ASSEMBLY
Paying attention to following work, assemble in reverse order of disassembly.
CAUTION:
lBe careful with orientation of insert spring.
SMT637A
SMT867D
Clearance
Standard : 0.95 - 1.4 mm (0.0374 - 0.055 in)
Limit value : 0.7 mm (0.028 in)
SMT140
SCIA0954E
Page 2622 of 3066

MT-86
FINAL DRIVE
FINAL DRIVE
PFP:38411
Assembly and Disassembly (RS5F51A)ECS004UR
PRE-INSPECTION
lCheck 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 gauge onto side gear. Move
side gear up and down, and measure the clearance.
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
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FINAL DRIVE
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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
lCheck 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
lCheck 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
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MT-88
FINAL DRIVE
4. Insert pinion mate shaft into differential case.
CAUTION:
Be sure not to damage pinion mate thrust washers.
5. Measure end play of side gears following procedure below.
Then select side gear thrust washer.
a. Upright the differential case so that its side gear to be measured
face upward.
b. Place final drive adapter and dial gauge onto side gears.
c. Move side gears up and down to measure end play, and select
thrust washer so that it satisfies standard.
CAUTION:
Place differential case upside down. Be sure to measure
end play for opposite side-gears likewise.
Thrust washer
CAUTION:
Only one thrust washer can be selected.
6. Using a pin punch (special service tool), drive a lock pin into the
pinion mate shaft.
CAUTION:
Do not reuse the lock pin.
MTK0132D
SMT610AG
Endplaystandardvalue
: 0.1 - 0.2 mm (0.004 - 0.008 in)
SMT611A
Thickness Part number
0.75 mm (0.0295 in)
0.80 mm (0.0315 in)
0.85 mm (0.0335 in)
0.90 mm (0.0354 in)
0.95 mm (0.0374 in)38424 81X00
38424 81X01
38424 81X02
38424 81X03
38424 81X04
SCIA0908E