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MAINSHAFT AND GEARS
MT-41
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• If any crack, damage, or excessive wear is found on cam face of
baulk ring or working face of insert, replace it.
Bearing
Check bearing for damage and rough rotation. If necessary, replace
with new one.
CAUTION:
Bearing preloading shim: after the intermediate adjusting shim
and/or the 6th main gear, 5th main gear, and 4th main gear have
been replaced, it is necessary to modify the bearing preload
setting by changing the bearing preload shim.
• When replacing tapered roller bearing, replace outer and inner
races as a set.
• Replacing the intermediate adjusting shim.
- Increase the size of the bearing preload shim, if the replaced
intermediate adjusting shim is thinner than the shim used before.
- Decrease the size of the bearing preload shim, if the replaced intermediate adjusting shim is thicker
than the shim used before.
• Replacing the 6th main gear, 5th main gear, and 4th main gear.
- Measure the thickness of the main gear used before and the new main gear.
- Increase the thickness of the bearing preload shim, if the difference is smaller than 0.025 mm (0.0010
in).
- Decrease the thickness of the bearing preload shim, if the difference is greater than 0.025 mm
(0.0010 in).
ASSEMBLY
1. Press-fit the mainshaft front bearing inner race (1) onto the
mainshaft using Tool (A).
2. Install 1st main gear (1), and 1st-2nd synchronizer assembly (2)
onto the mainshaft.
3. Press-fit the bushing (3) onto the mainshaft using Tool (A).
SCIA0608J
SPD715
Tool number : ST36720030 ( — )
PCIB1733E
Tool number : KV32102700 ( — )
PCIB1734E
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MT-42
< SERVICE INFORMATION >
MAINSHAFT AND GEARS
4. Press-fit 3rd main gear (1) onto the mainshaft with Tool (A) after
installing the 2nd main gear (2) and the 3rd main gear (1) onto
the mainshaft.
5. Select the thickness of the intermediate adjusting shim (1)
needed by measuring the distance “L” between the base of the
mainshaft (2) and the top of the 3rd main gear (3). Refer to the
following table to determine the thickness of the adjusting shim.
Unit: mm (in)
6. Install selected intermediate adjusting shim.
7. Press-fit the 4th main gear (1) onto the mainshaft using Tool (A).
8. Press-fit the 5th main gear (1) onto the mainshaft using Tool (A).Tool number : KV32102700 ( — )
PCIB1735E
Distance “L” Adjusting shim thickness
147.690 – 147.666 (5.8146 – 5.8136) 1.500 (0.0591)
147.665 – 147.641 (5.8136 – 5.8126) 1.525 (0.0600)
147.640 – 147.616 (5.8126 – 5.8116) 1.550 (0.0610)
147.615 – 147.591 (5.8116 – 5.8107) 1.575 (0.0620)
147.590 – 147.566 (5.8106 – 5.8097) 1.600 (0.0630)
147.565 – 147.541 (5.8096 – 5.8087) 1.625 (0.0640)
147.540 – 147.516 (5.8086 – 5.8077) 1.650 (0.0650)
147.515 – 147.491 (5.8077 – 5.8067) 1.675 (0.0659)
147.490 – 147.466 (5.8067 – 5.8057) 1.700 (0.0669)
147.465 – 147.441 (5.8057 – 5.8048) 1.725 (0.0679)
147.440 – 147.416 (5.8047 – 5.8038) 1.750 (0.0689)
147.415 – 147.391 (5.8037 – 5.8028) 1.775 (0.0699)
PCIB1736E
Tool number : KV32102700 ( — )
PCIB1737E
Tool number : KV32102700 ( — )
PCIB1738E
Page 2331 of 2771
MAINSHAFT AND GEARS
MT-43
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9. Press-fit the 6th main gear (1) onto the mainshaft using Tool (A).
10. Press-fit the mainshaft rear bearing inner race (1) onto the main-
shaft using Tool (A).
11. Install snap ring onto mainshaft.Tool number : KV32102700 ( — )
PCIB1739E
Tool number : ST30901000 (J-26010-01)
PCIB1740E
Page 2332 of 2771
MT-44
< SERVICE INFORMATION >
REVERSE IDLER SHAFT AND GEARS
REVERSE IDLER SHAFT AND GEARS
Disassembly and AssemblyINFOID:0000000001703145
DISASSEMBLY
1. Remove reverse output gear (1).
2. Remove snap ring (1).
3. Remove reverse baulk ring (1) and return spring (2).
4. Remove snap ring (1), lock washer (2), reverse input gear (3)
and washer.
PCIB1760E
PCIB1759E
PCIB1758E
PCIB1757E
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REVERSE IDLER SHAFT AND GEARS
MT-45
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5. Remove needle bearings (1) from reverse idler shaft.
ASSEMBLY
Assembly is in the reverse order of disassembly.
CAUTION:
• Do not reuse snap ring.
• Make sure that snap ring is securely installed in the groove.
PCIB1761E
Page 2334 of 2771
MT-46
< SERVICE INFORMATION >
FINAL DRIVE
FINAL DRIVE
Disassembly and AssemblyINFOID:0000000001703146
DISASSEMBLY
1. Remove differential side bearing inner race (clutch housing side)
(1) using Tool (A) and suitable tool.
2. Remove speedometer drive gear.
3. Remove final gear bolts (1), and then separate the final gear (2)
from differential case.
4. Remove differential side bearing inner race (transaxle case
side) (1) using suitable tool (A).
5. Remove lock ring (1) from differential case.
6. Remove pinion mate shaft, pinion mate gears, side gears and
thrust washer from differential case.
INSPECTION AFTER DISASSEMBLY
Gear, Washer, Shaft and Case
Tool number : ST33061000 (J-8107-2)
PCIB1767E
PCIB1766E
PCIB1765E
PCIB1764E
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FINAL DRIVE
MT-47
< SERVICE INFORMATION >
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• Check side gears, thrust washer, pinion mate shaft, pinion mate
gears, lock ring 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. Install pinion mate shaft, pinion mate gears, side gears and thrust washer into differential case.
2. Install lock ring (1) onto differential case.
CAUTION:
Make sure that lock ring is securely installed in the groove.
3. Install final gear into differential case, and tighten final gear bolts
to specification. Refer to MT-17, "
Disassembly and Assembly".
4. Install speedometer drive gear onto differential case.
5. Press-fit the differential side bearing inner race (clutch housing
side) onto the differential case using suitable tool (A).
PCIB0977J
SPD715
PCIB1764E
PCIB1762E
Page 2336 of 2771
MT-48
< SERVICE INFORMATION >
FINAL DRIVE
6. Press-fit the differential side bearing inner race (transaxle case
side) onto the differential case using suitable tool (A).
PCIB1763E