Drive Pinion Shaft Assembly: Disassembly

CAUTION: Attach a cloth to the end of driven shaft (on the frictional side of thrust needle bearing) during disassembly or reassembly to prevent damage.

Straighten lock nut at staked portion. Remove the lock nut using ST1, ST2 and ST3.
ST1 899884100 HOLDER

ST2 498427100 STOPPER

ST3 899988608 SOCKET WRENCH

Fig 1: Removing Lock Nut
Withdraw drive pinion from driven shaft.
Remove differential bevel gear sleeve, adjusting washer No. 1, adjusting washer No. 2, thrust bearing, needle bearing, drive pinion collar, needle bearing and thrust bearing.

Fig 2: Removing Drive Pinion Shaft Components
Remove roller bearing and washer (33 x 50 x 5) using ST and press.

CAUTION: Do not reuse roller bearing.

Fig 3: Removing Roller Bearing And Washer (33 X 50 X 5)

ST 498077000 REMOVER
Straighten lock nut at staked portion. Remove the lock nut using ST1 and ST2.
ST1 499987300 SOCKET WRENCH (50)

ST2 899884100 HOLDER

Fig 4: Removing Lock Nut
Remove 5th driven gear using ST.
ST 499857000 5TH DRIVEN GEAR REMOVER

Fig 5: Removing 5th Driven Gear
Remove woodruff key.
Remove roller bearing (42 x 74 x 40), 3rd-4th driven gear using ST1 and ST2.
ST1 499757002 SNAP RING PRESS

ST2 899714110 REMOVER

Fig 6: Removing Roller Bearing (42 x 74 x 40)
Remove the key.
Remove 2nd driven gear, inner baulk ring, synchro cone and outer baulk ring.

Fig 7: Removing 2nd Driven Gear Components
Remove 1st driven gear, 2nd gear bushing, gear and hub using ST1 and ST2.
NOTE: Replace gear and hub if necessary. Do not attempt to disassemble if at all possible because they must engage at a specified point. If they have to be disassembled, mark the engaging point before hand.

ST1 499757002 SNAP RING PRESS

ST2 899714110 REMOVER

Fig 8: Removing 1st Driven Gear, 2nd Gear Bushing, Gear And Hub
Remove sub gear for 1st driven gear.