Drive Pinion Shaft Assembly
Drive Pinion Shaft AssemblyREMOVAL
Remove the transmission assembly from vehicle.
Extract the torque converter clutch assembly.
Remove the input shaft.
Lift-up lever behind the transmission harness connector and disconnect it from stay.
Disconnect inhibitor switch connector from stay.
Disconnect the air breather hose.
Remove the oil charge pipe.
Remove the oil cooler inlet and outlet pipes.
Separation of converter case and transmission case sections
Separate transmission case and extension case sections.
Remove the reduction drive gear. (MPT model)
Remove the center differential carrier. (VTD model)
Remove the reduction driven gear.
Remove the drive pinion shaft mounting bolt and remove the drive shaft assembly from oil pump housing.
INSTALLATION
Assemble the drive pinion assembly to the oil pump housing.
Note:
^ Pay attention not to bend the shim.
^ Pay attention not to press the pinion into housing bore.
Tightening torque: 40 Nm (4.0 (kgf-m, 30 ft. lbs.)
Combine the torque converter case with the transmission case.
Install the reduction driven gear.
Install the reduction drive gear. (MPT model)
Install the center differential carrier. (VTD model)
Combine the extension case with the transmission case, and install vehicle speed sensor 1 (rear).
Insert inhibitor switch and transmission connector into stay.
Install the oil cooler inlet and outlet pipes.
Install the oil charge pipe with O-rings
Insert the input shaft while turning lightly by hand and verify the protrusion amount.
Normal protrusion A: 50 - 55 mm (1.97 - 2.17 inch)
Install the torque converter clutch assembly.
Install the transmission assembly to vehicle.
DISASSEMBLY
Straighten the staked portion of the lock nut, and remove the lock nut while locking the rear spline portion of the shaft with ST1 and ST2. Then pull off the drive pinion collar.
ST1 32005120 HOLDER
ST2 32005154 WRENCH
ST3 32005153 ADAPTER
Remove the O-ring.
Using a press, separate the rear roller bearing and outer race from the shaft.
(A) Outer race
Using a press and ST, separate the front roller bearing from the shaft.
ST32005108 REPLACER
(A) Front roller bearing
ASSEMBLY
Measure dimension A of the drive pinion shaft.
ST 32005073 GAUGE
Using a press, force-fit a new roller bearing in position.
Note: If too much pressure is applied, the roller bearing will not turn easily.
(A) Drive pinion shaft
(B) Roller bearing
After fitting a new O-ring to the shaft, attach the drive pinion collar to the shaft.
Install the lock washer to drive pinion shaft in proper direction.
Tighten a new lock nut with ST1, ST2 and ST3.
Calculate lock washer and lock nut specifications using the following formula.
T2 = L2/(L1 + L2) x T1
T1: 116 Nm (11.8 (kgf-m, 85.3 ft. lbs.)
[Required torque setting]
T2: Tightening torque
L1: ST2 length 0.072 m (2.83 inch)
L2: Torque wrench length
Torque Wrench Length (Part 1):
Torque Wrench Length (Part 2):
Example:
ST1 32005120 HOLDER
ST2 32005154 WRENCH
ST3 32005153 ADAPTER
Note: Install ST2 to torque wrench as straight as possible.
Measure the starting torque of the bearing. Make sure the starting torque is within the specified range. If out of the allowable range, replace the roller bearing.
Starting torque: 7.6 - 38.1 N (0.776 - 3.88 kgf, 1.7 - 8.6 lbs.)
Stake the lock nut securely at two places.
Measure dimension "B" of the drive pinion shaft.
ST 32005073 GAUGE
The thickness "t" (mm) of the drive pinion shim.
t: = 6.5±0.0625 - (B - A)
Select three or less shims from following table.
Available drive pinion shims (Part 1):
Available drive pinion shims (Part 2):
INSPECTION
^ Make sure that all component parts are free of harmful cuts, gouges, and other faults.
^ Adjust the teeth alignment.
ADJUSTMENT
Thoroughly remove the liquid gasket from the case mating surface beforehand.
Install the oil pump housing assembly to the converter case, and secure evenly by tightening four bolts.
Note: Use an old gasket or an aluminum washer so as not to damage the mating surface of the housing.
Tightening torque: 41 Nm (4.2 (kgf-m, 30.4 ft. lbs.)
Rotate the drive pinion several times with ST1 and ST2.
ST1 32005120 HOLDER
ST2 32005154 WRENCH
Adjust the backlash between drive pinion and hypoid driven gear.
Apply red lead evenly to the surfaces of three or four teeth of the hypoid driven gear. Rotate the drive pinion in the forward and reverse directions several times. Then remove the oil pump housing, and check the tooth contact pattern.
If tooth contact is improper, readjust the backlash or shim thickness.
^ Tooth contact
Checking item: Tooth contact pattern is slightly shifted toward to toe side under no-load rotation. [When loaded, contact pattern moves toward heel.]
(A) Toe side
(B) Heel side
^ Face contact
Checking item: Backlash is too large.
Contact pattern
Corrective action: Increase thickness of drive pinion height adjusting washer in order to bring drive pinion close to hypoid driven gear.
^ Flank contact
Checking item: Backlash is too small.
Contact pattern
Corrective action: Reduce thickness of drive pinion height adjusting washer in order to move drive pinion away from hypoid driven gear.
^ Toe contact (Inside end contact)
Checking item: Contact areas is small.
Contact pattern
Corrective action: Decrease thickness of drive pinion height adjusting washer in order to move drive pinion away from hypoid driven gear.
^ Heel contact (Outside end contact)
Checking item: Contact areas is small.
Contact pattern
Corrective action: Increase thickness of drive pinion height adjusting washer in order to move drive pinion close to hypoid driven gear.
^ If tooth contact is correct, mark the retainer position and loosen it. After fitting a new O-ring and oil seal, screw in the retainer to the marked position. Then tighten the lock plate to the specified torque.
Tightening torque: 25 Nm (2.5 (kgf-m, 18.1 ft. lbs.)
(A) Lock plate