Drive Pinion: Assembly

Install the plug to the drive pinion retainer with a new O-ring.
NOTE: Apply CVTF to the O-rings.

Tightening torque:

22 N.m (2.2 kgf.m, 16.2 ft.lb)
Using the ST, install the oil seal.
NOTE:
- Apply CVTF to the press-fitting surface of oil seal and apply differential gear oil to the lip portion.
- Make sure to install in the right direction.
Preparation tool:

ST: HOUSING BUSHING INSTALLER AND REMOVER (927720000)

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Select the drive pinion washer.

Measure width "A" of a new taper roller bearing (front) inner race.

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Measure width "B" of a new taper roller bearing (rear) inner race.

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Measure width "C" of the drive pinion spacer.

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Press-fit a new taper roller bearing (front) outer race using the ST1, ST2 and a press.

Preparation tool:

ST1: PRESS SNAP RING (28499TC010)

ST2: INSTALLER (398177700)

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Press-fit a new taper roller bearing (rear) outer race using the ST and a press.

Preparation tool:

ST: INSTALLER (20099AE020)

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Place the drive pinion retainer on the surface plate, and install the taper roller bearing (rear) inner race to the taper roller bearing (rear) outer race.
NOTE: Place the drive pinion retainer so that the mating surface of the drive pinion retainer (mating surface with the converter case) contacts the surface plate.

Measure the height "D" from the end face of the taper roller bearing (rear) inner race to the surface plate.

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Install the taper roller bearing (front) inner race to the taper roller bearing (front) outer race.

Measure the depth "E" from the end face of the taper roller bearing (front) inner race to the end face of the ST.

Preparation tool:

ST: GAUGE (499575400)

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Using following formula, select one to three drive pinion washers.
T mm = D - (A + B + C + E - 15) - (0±0.0125)

[T in = D - (A + B + C + E - 0.591) - (0±0.0005)]

A: Width of taper roller bearing (front) inner race

B: Width of taper roller bearing (rear) inner race

C: Width of drive pinion spacer

D: Height from end face of taper roller bearing (rear) inner race to surface plate

E: Depth from the end face of the taper roller bearing (front) inner race to the end face of the ST

15 mm (0.591 in): Thickness of ST

T: Drive pinion washer thickness

0±0.0125 mm (0±0.0005 in): Clearance

Measure and record the drive pinion shim thickness to be reused. When reuse is not possible, select the drive pinion shim.

Using a precise round bar, measure the height "G" from the mating surface of transmission case of the converter case to the upper end of the round bar. Also, measure and record the diameter "M" of the round bar.

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Using the following formula, calculate the height "A1" from the mating surface of the converter case and transmission case to the bottom end of the differential side retainer hole.
A1 mm = G - M

[A1 in = G - M]

G: Height from the mating surface of the converter case and transmission case to the upper end of the round bar

M: Diameter of the round bar

Measure the hole inner diameter "R" of differential side retainer of the converter case.

NOTE: Perform the measurement at the contact surface of the side bearing outer race.

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Using the following formula, calculate the hole radius "A2" of the differential side retainer.
A2 mm = R/2

[A2 in = R/2]

R: Hole inner diameter of differential side retainer of the converter case

Using the following formula, calculate the differential center distance "A" from the mating surface of the converter case and transmission case.

A mm = A1 + A2

[A in = A1 + A2]

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Measure the depth "B1" from the ST to the mating surface of drive pinion retainer. Then, using the following formula, calculate the height "B" from the mating surface of transmission case of the converter case to the mating surface of drive pinion retainer.

Preparation tool:

ST: GAUGE (499575400)

B mm = B1 - 15

[B in = B1 - 0.591]

B1: Depth from ST to the drive pinion retainer mating surface

15 mm (0.591 in): Thickness of ST

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Using following formula, select one to three drive pinion shims.

T mm = (A - B + E - 15) - 90.8 + (0±0.0125)

[T in = (A - B + E - 0.591) - 3.575 + (0±0.0005)]

A: Differential center distance from the mating surface of the converter case and transmission case

B: Height from the mating surface of the converter case and transmission case to the mating surface of the drive pinion retainer

E: Depth from the end face of the taper roller bearing (front) inner race to the end face of the ST, measured in (9) in "3. Select the drive pinion washer"

15 mm (0.591 in): Thickness of ST

T: Drive pinion shim thickness

90.8 mm (3.575 in): Ideal distance from the differential center to the drive pinion end surface

0±0.0125 mm (0±0.0005 in): Clearance

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Install the drive pinion shim that is reused for the drive pinion.
Press-fit the taper roller bearing (front) inner race using the ST1, ST2 and a press.
Preparation tool:

ST1: INSTALLER (899580100)

ST2: EXTENSION DRIVE SHAFT (927130000)

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Install the drive pinion spacer.
NOTE: Replace the O-ring with a new part after tooth contact inspection.

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Install the selected drive pinion washer.

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Insert the drive pinion into the drive pinion retainer.
CAUTION: Be careful not to damage the oil seal.
Install the lock nut.
NOTE: Apply differential gear oil to the threaded portion of the drive pinion.

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Using the ST1, ST2 and ST3, tighten the lock nut to the specified torque so that the initial load of the drive pinion is within the specified range.

CAUTION: Before inspecting the starting torque, apply differential gear oil to roller of bearing and rotate the taper roller bearing several times.

NOTE:

Tighten the lock nut while directly aligning ST2 and torque wrench.
If the initial load is not within the specified range, select the drive pinion washer, and repeat the step until the initial load is within the specified range.
When a thicker drive pinion washer is selected, the initial load decreases. When a thinner drive pinion washer is selected, the initial load increases.

Initial load:

5.1 - 17.1 N (0.5 - 1.7 kgf, 1.1 - 3.8 lbf)

Preparation tool:

ST1: ADAPTER (499787500)

ST2: WRENCH (499787700)

ST3: HOLDER (498937110)

Using the following formula, calculate the tightening torque for a torque wrench.

T2 = L2/(L1 + L2) x T1

T1: 170 - 250 N.m (17.3 - 25.5 kgf-m, 125.4 - 184.4 ft-lb) [Specified tightening torque range]

T2: Tightening torque

L1: ST1 length 0.072 m (2.83 in)

L2: Torque wrench length

Example:

Torque wrench length m (in)	Tightening torque N.m (kgf-m, ft-lb)
0.4 (15.75)	144 - 211 (14.7 - 21.5, 106.2 - 155.6)
0.45 (17.72)	147 - 215 (15.0 - 21.9, 108.4 - 158.6)
0.5 (19.69)	149 - 218 (15.2 - 22.2, 109.9 - 160.8)
0.55 (21.65)	150 - 221 (15.3 - 22.5, 110.6 - 163.0)

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Install the drive pinion retainer to the converter case, and check the backlash and tooth contact of the hypoid gear set. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR580)>Drive Pinion>ADJUSTMENT . Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR580)>Front Differential>ADJUSTMENT .
Remove the drive pinion retainer from converter case. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR580)>Drive Pinion>REMOVAL .
Remove the drive pinion spacer from the drive pinion. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR580)>Drive Pinion>DISASSEMBLY .
Install a new O-ring.
NOTE: Apply the differential gear oil to O-ring.

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Install the drive pinion spacer.

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Install the drive pinion washer.

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Insert the drive pinion.
CAUTION: Be careful not to damage the oil seal.

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Install a new lock nut.
NOTE: Apply differential gear oil to the threaded portion of the drive pinion.

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Using the ST1, ST2 and ST3, tighten the lock nut to the specified torque so that the initial load of the drive pinion is within the specified range.

CAUTION: Before inspecting the initial load, apply differential gear oil to the roller of the taper roller bearing (front) and taper roller bearing (rear), and rotate the taper roller bearing several times.

NOTE:

Tighten the lock nut while directly aligning ST2 and torque wrench.
If the initial load is not within the specified range, select the drive pinion washer, and repeat the step until the initial load is within the specified range.
When a thicker drive pinion washer is selected, the initial load decreases. When a thinner drive pinion washer is selected, the initial load increases.

Initial load:

5.1 - 17.1 N (0.5 - 1.7 kgf, 1.1 - 3.8 lbf)

Preparation tool:

ST1: ADAPTER (499787500)

ST2: WRENCH (499787700)

ST3: HOLDER (498937110)

Using the following formula, calculate the tightening torque for a torque wrench.

T2 = L2/(L1 + L2) x T1

T1: 170 - 250 N.m (17.3 - 25.5 kgf-m, 125.4 - 184.4 ft-lb) [Specified tightening torque range]

T2: Tightening torque

L1: ST1 length 0.072 m (2.83 in)

L2: Torque wrench length

Example:

Torque wrench length m (in)	Tightening torque N.m (kgf-m, ft-lb)
0.4 (15.75)	144 - 211 (14.7 - 21.5, 106.2 - 155.6)
0.45 (17.72)	147 - 215 (15.0 - 21.9, 108.4 - 158.6)
0.5 (19.69)	149 - 218 (15.2 - 22.2, 109.9 - 160.8)
0.55 (21.65)	150 - 221 (15.3 - 22.5, 110.6 - 163.0)

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Crimp the lock nut.
Press-fit a new plug using ST1, ST2 and a press.
Preparation tool:

ST1: PRESS SNAP RING (499755602)

ST2: INSTALLER (398177700)

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