Drive Pinion Shaft Assembly: Disassembly

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

NOTE:

Attach a cloth to the end of driven shaft (on the frictional side of the thrust needle bearing) to prevent damage during disassembly or reassembly.
When replacing the coupling sleeve and synchronizer hub, replace them as a set.
Because these must engage at the specified point, avoid disassembly as much as possible. If it is necessary to disassemble, mark the engaging points on the splines beforehand.

Using ST1, ST2 and ST3, remove the lock nut.
NOTE: Flatten the lock nut tab before removing the lock nut.

Preparation tool: ST1: HOLDER (18680AA020)

ST2: HOLDER (18667AA020)

ST3: SOCKET (27) (18662AA010)

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Remove the lock washer, washer, differential bevel gear sleeve, adjusting washer No. 1, thrust bearing and adjusting washer No. 2.

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Draw out the drive pinion shaft from driven shaft.
Remove the needle bearing and drive pinion collar.

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Remove the needle bearing and thrust bearing.

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Remove the roller bearing and washer using ST and a press.
Preparation tool: ST: REMOVER (498077000)

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Using ST1 and ST2, remove the lock nut.
NOTE: Flatten the lock nut tab before removing the lock nut.

Preparation tool: ST1: SOCKET WRENCH (50) (499987300)

ST2: HOLDER (18680AA020)

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Remove the ball bearing, 6th driven gear and drive pinion spacer using the ST1, ST2 and a press.
Preparation tool: ST1: PRESS (899754112)

ST2: REMOVER (899714110)

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Remove the 5th driven gear, double ball bearing and 3rd-4th driven gear using ST1, ST2 and a press.
Preparation tool: ST1: PRESS (899754112)

ST2: REMOVER (899714110)

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Remove the key.
Remove the 2nd driven gear, 2nd inner baulk ring, 2nd synchro cone, 2nd outer baulk ring, 1st-2nd shifting insert and 1st-2nd coupling sleeve.
CAUTION: When removing 1st-2nd coupling sleeve, be careful not to lose the 1st-2nd shifting insert.
Remove the 1st driven gear, 1st inner baulk ring, 1st synchro cone, 1st outer baulk ring, 2nd driven gear bushing and 1st-2nd synchronizer hub using ST and a press.
Preparation tool: ST: COMPRESSOR SPECIAL TOOL (18762AA001)

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