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INSTALLATION

INSTALLATION

Remove the differential assembly.

Alignment marks/numbers on hypoid gear set:

The upper number on drive pinion is the match number for combining it with hypoid driven gear. The lower number is for shim adjustment. If no lower number is shown, the value is zero. The number on hypoid driven gear indicates a number for combination with drive pinion.


(A)

Match number

(B)

Shim adjust number



Place the drive pinion shaft assembly on right hand transmission main case without shim and tighten the bearing mounting bolts.

Inspection and adjustment of ST:

Note
Loosen the two bolts and adjust so that the scale indicates 0.5 correctly when the plate end and the scale end are on the same level.

Tighten the two bolts.


ST 32005160 DRIVE PINION GAUGE ASSY


(A)

Plate

(B)

Scale



Position the ST by inserting the knock pin of ST into the knock hole in transmission case.

ST 32005160 DRIVE PINION GAUGE ASSY

Slide the drive pinion gauge scale with finger tip and read the value at the point where it matches with the end face of drive pinion.

ST 32005160 DRIVE PINION GAUGE ASSY


(A)

Adjust clearance to zero without shim.



The thickness of shim shall be determined by adding the value indicated on drive pinion to the value indicated on ST. (Add if the number on drive pinion is prefixed by + and subtract if the number is prefixed by −.)

ST 32005160 DRIVE PINION GAUGE ASSY

Select one to three shims from the next table for the value determined as described above and take a shim thickness which is closest to the indicated value.

Drive pinion shim
Part No. Thickness mm (in)
32006727

0.150 (0.0059)

32006728

0.175 (0.0069)

32006729

0.200 (0.0079)

32006730

0.225 (0.0089)

32006731

0.250 (0.0098)

32006732

0.275 (0.0108)

32006733

0.300 (0.0118)

32006734

0.500 (0.0197)



Install the differential assembly.

Set the transmission main shaft assembly and drive pinion assembly in position. (So there is no clearance between the two when moved all the way to the front). Inspect the suitable 1st-2nd, 3rd-4th and 5th shifter fork so that coupling sleeve and reverse driven gear are positioned in the center of their synchronizing mechanisms.

Install the transmission case.

Install the transfer case with extension case assembly.

Install the manual transmission assembly to vehicle.