Drive Pinion Shaft Assembly: Assembly

WARNING: This page is about a different variant/trim than selected.

NOTE:

Match the alignment marks, and install the coupling sleeve and then install the shifting insert.
Make sure that there is no large clearance at both sides of the shifting insert after assembly.

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Install the 1st driven gear, 1st inner baulk ring, 1st synchro cone, 1st outer baulk ring and 1st-2nd synchronizer hub.
NOTE:
- Install the 1st-2nd synchronizer hub in proper direction.
- Align the protrusion of the 1st outer baulk ring into the groove of the 1st-2nd synchronizer hub.
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Install the 2nd driven gear bushing using ST and a press.
CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
NOTE:
- Attach a cloth to the end of the driven shaft to prevent damage.
- When press fitting, align the oil holes of the driven shaft and 2nd driven gear bushing.
Preparation tool:

ST: INSTALLER (18654AA000)

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Install the 1st-2nd coupling sleeve.
NOTE:
- Install the 1st-2nd coupling sleeve in proper direction.
- Align the alignment marks of 1st-2nd coupling sleeve and the 1st-2nd synchronizer hub.
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Install the 1st-2nd shifting insert.
NOTE: Press in the ball part to install.

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Install the 2nd outer baulk ring, 2nd synchro cone, 2nd inner baulk ring and 2nd driven gear.

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Install the key to the driven shaft.
Using the ST and a press, install the 3rd-4th driven gear.
CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
NOTE:
- Match the groove on the 3rd-4th driven gear to the key.
- Install the 3rd-4th driven gear in the proper direction.
Preparation tool:

ST: INSTALLER (499277200)

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Using the ST and a press, install a new double ball bearing.
CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

Preparation tool:

ST: INSTALLER (499277200)

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Using the ST and a press, install the 5th driven gear.
CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

NOTE: Install the 5th driven gear with the groove side facing the 6th driven gear.

Preparation tool:

ST: INSTALLER (499277200)

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Install the drive pinion spacer to the driven shaft.
Using the ST and a press, install the 6th driven gear.
CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

NOTE: Install with the stepped side on the end surface of the 6th driven gear facing the rear ball bearing side.

Preparation tool:

ST: INSTALLER (499277200)

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Using the ST and a press, install the ball bearing.
CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

Preparation tool:

ST: INSTALLER (499277200)

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Install a new lock nuts using ST1 and ST2.
Tightening torque:

440 N.m (44.9 kgf-m, 324.5 ft-lb)

Preparation tool:

ST1: SOCKET WRENCH (50) (499987300)

ST2: HOLDER (18680AA020)

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Using a spring scale, check that the initial load of the ball bearings is 0.1 - 1.5 N (0.01 - 0.15 kgf, 0.02 - 0.34 lbf).

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Crimp the lock nut at two locations so that the dimension (B) becomes 39.1 mm (1.54 in) or less.
CAUTION: When crimping the lock nut, be careful not to crack it.

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Install a new roller bearing.
NOTE: Install the knock pin hole of the roller bearing outer race, facing the rear side.

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Install the washer using ST1, ST2 and a press.
CAUTION: Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

Preparation tool:

ST1: BUSHING 1-2 INSTALLER (499277100)

ST2: INSTALLER (499277200)

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Install the thrust bearing and needle bearing and install the driven shaft assembly.

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Install the drive pinion collar, needle bearing, adjusting washer No. 2, thrust bearing, adjusting washer No. 1 and differential bevel gear sleeve in this order.

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Adjust the thrust bearing preload. Refer to MANUAL TRANSMISSION AND DIFFERENTIAL (6MT)>DRIVE PINION SHAFT ASSEMBLY>ADJUSTMENT>THRUST BEARING PRELOAD .