Drive Pinion Shaft Assembly: Assembly

Assemble gear and hub assembly.
NOTE:
- Use new gear and hub assembly, if gear or hub have been replaced.
- Be sure the insert keys are correctly located in the insert key grooves inside the reverse driven gear.
Fig 1: Assembling Gear And Hub Assembly

Fig 2: Identifying 1st & 2nd Gear Side Configurations
Install sub gear to 1st driven gear.
Install 1st driven gear, 1st baulk ring, gear and hub assembly onto driven shaft.
NOTE:
- Take care to install gear and hub assembly in proper direction.
- Align baulk ring and gear & hub assembly with key groove.
Install 2nd driven gear bushing onto driven shaft using ST1, ST2 and press.
CAUTION:
- Attach a cloth to the end of driven shaft to prevent damage.
- Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
NOTE: When press fitting, align oil holes of shaft and bush.

ST1 499277200 INSTALLER

ST2 499587000 INSTALLER

Fig 3: Installing 1st Driven Gear, 1st Baulk Ring, Gear And Hub Assembly
Install 2nd driven gear, inner baulk ring, synchro cone, outer baulk ring and insert onto driven shaft.

Fig 4: Installing 2nd Driven Gear, Inner Baulk Ring, Synchro Cone & Outer Baulk Ring
After installing key on driven shaft, install 3rd-4th driven gear using ST and press.
CAUTION: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

NOTE: Align groove in baulk ring with insert.

ST 499277200 INSTALLER

Fig 5: Installing Key On Driven Shaft & 3rd-4th Driven Gear
Install a set of roller bearings (42 x 74 x 40) onto the driven shaft using ST and press.
CAUTION: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

ST 499277200 INSTALLER

Fig 6: Installing Roller Bearings (42 X 74 X 40) Onto The Driven Shaft
Position woodruff key in groove on the rear of driven shaft. Install 5th driven gear onto drive shaft using ST and press.
CAUTION: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

ST 499277200 INSTALLER

Fig 7: Installing 5th Driven Gear
Install lock washer (42 x 53 x 2). Install lock nut (42 x 13) and tighten to the specified torque using
ST.

ST 499987300 SOCKET WRENCH (50)

Tightening torque:
1. 265+/-10 N.m (27+/-1 kgf-m, 195+/-7 ft-lb)
  
  Fig 8: Installing Lock Washer (42 X 53 X 2). Install Lock Nut (42 X 13)
NOTE:
- Stake lock nut at two points.
- Using spring balancer, check that starting torque of roller bearing is 0.1 to 1.5 N.m (0.01 to 0.15 kgf-m, 0.07 to 1.08ft-lb).
Fig 9: Checking Starting Torque Of Roller Bearing
Install roller bearing onto drive pinion.
NOTE: When installing roller bearing, note its directions (front and rear) because knock pin hole in outer race is offset.

Fig 10: Installing Roller Bearing Onto Drive Pinion
Install washer (33 x 50 x 5) using ST1, ST2 and press.
CAUTION: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

ST1 499277100 BUSH 1-2 INSTALLER

ST2 499277200 INSTALLER

Fig 11: Installing Washer (33 X 50 X 5)
Install thrust bearing (33 x 50 x 3) and needle bearing (30 x 37 x 23). Install driven shaft assembly.

Fig 12: Installing Driven Shaft Assembly
Install drive pinion collar, needle bearing, adjusting washer No. 2, thrust bearing, adjusting washer No. 1 and differential bevel gear sleeve in that order.
NOTE: Be careful because spacer must be installed in proper direction.

Fig 13: Identifying Driven Shaft & Drive Shaft Components