Transmission Case: Installation

Wipe off grease, oil and dust on the mating surfaces of transmission cases with white gasoline, and apply liquid gasket, and then put case right side and left side together.
Liquid gasket:
1. THREE BOND 1215 or equivalent
Tighten 17 bolts with bracket, clip etc. as shown in the figure.
NOTE:
- Insert bolts from the bottom and tighten nuts at the top.
- Put cases together so that drive pinion shim and input shaft holder shim are not caught up in between.
- Confirm that speedometer gear is meshed.
Tightening torque:
1. 8 mm bolt
  25 N.m (2.5 kgf-m, 18.1 ft-lb)
- 10 mm bolt
  39 N.m (4.0 kgf-m, 28.9 ft-lb)
  
  Fig 1: Identifying Bolt Locations
Tighten ball bearing attachment bolts.
Tightening torque:
1. 29 N.m (3.0 kgf-m, 21.7 ft-lb)
  
  Fig 2: Tightening Ball Bearing Attachment Bolts
Backlash adjustment of hypoid gear and preload adjustment of roller bearing
NOTE: Support drive pinion assembly with ST.

ST 498427100 STOPPER

Fig 3: Supporting Drive Pinion Assembly With ST
Place the transmission with case left side facing downward and put ST1 on bearing cup.
Screw retainer assembly into left case from the bottom with ST2. Fit ST3 on the transmission main shaft. Shift gear into 4th or 5th and turn the shaft several times. Screw in the retainer while turning ST3 until a slight resistance is felt on ST2.
This is the contact point of hypoid gear and drive pinion shaft. Repeat the above sequence several times to ensure the contact point.

ST1 399780104 WEIGHT

ST2 499787000 WRENCH ASSY

ST3 499927100 HANDLE

Fig 4: Identifying Special Tools
Remove weight and screw in retainer without O-ring on the upper side and stop at the point where slight resistance is felt.
NOTE: At this point, the backlash between the hypoid gear and drive pinion shaft is zero.

ST 499787000 WRENCH ASSY

Fig 5: Identifying ST 499787000 Wrench Assy
Fit lock plate. Loosen the retainer on the lower side by 1-1/2 notches of lock plate and turn in the retainer on the upper side by the same amount in order to obtain the backlash.
NOTE: The notch on the lock plate moves by 1/2 notch if the plate is turned upside down.
Turn in the retainer on the upper side additionally by 1 notch in order to apply preload on taper roller bearing.
Tighten temporarily both the upper and lower lock plates and mark both holder and lock plate for later readjustment.
Turn transmission main shaft several times while tapping around retainer lightly with plastic hammer.
Inspect and adjust backlash and tooth contact of hypoid gear. See INSPECTION .
After checking the tooth contact of hypoid gears, remove the lock plate. Then loosen retainer until the O-ring groove appears. Fit O-ring into the groove and tighten retainer into the position where retainer has been tightened in.
Tighten lock plate.

NOTE: Carry out this job on both upper and lower retainers.

Tightening torque:
1. T: 25 N.m (2.5 kgf-m, 18.1 ft-lb)
  
  Fig 6: Installing Retainer
Selecting of main shaft rear plate Using ST, measure the amount (A) of ball bearing protrusion from transmission main case surface and select the proper plate in the following table:
NOTE: Before measuring, tap the end of main shaft with a plastic hammer lightly in order to make the clearance zero between the main case surface and the moving flange of bearing.

ST 498147000 DEPTH GAUGE

Fig 7: Main Shaft Rear Plate Chart

Fig 8: Measuring The Amount (A) Of Ball Bearing Protrusion
Install clutch release lever and bearing. See INSTALLATION .
Install transfer case with extension case assembly. See Transfer Case and Extension Case Assembly .
Install the manual transmission assembly into the vehicle. See Manual Transmission Assembly .