Drive Pinion Shaft Assembly: Assembly

1. Install the plug to drive pinion retainer.
   NOTE:

   • Use new O-rings.
   • Apply CVTF to the O-rings.

   Tightening torque: 

   22 N.m (2.2 kgf-m, 16.2 ft-lb)

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2. Using the ST, install the oil seal to drive pinion retainer.
   NOTE:

   • Apply CVTF to the oil seal press-fitting surface and lip.
   • Install the oil seal in the correct direction.

   ST 927720000 HOUSING BUSHING INSTALLER AND REMOVER 

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3. Select the drive pinion washer.
   1. Measure the roller bearing inner race width "A" on the front side.

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   2. Measure the roller bearing inner race width "B" on the rear side.

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   3. Measure the spacer width "C".

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   4. Using the ST, install the front roller bearing outer race to the drive pinion retainer.

      ST1 28499TC010 INSTALLER 

      ST2 398177700 INSTALLER 

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   5. Using the ST, install the rear roller bearing outer race to the drive pinion retainer.

      ST 20099AE020 INSTALLER 

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   6. Place the drive pinion retainer on the surface plate, and install the inner race to the rear roller bearing 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.
   7. Measure the height "D" from the end face of the rear roller bearing inner race to the surface plate.

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   8. Install the inner race to the front roller bearing outer race.
   9. Measure the depth "E" from the end face of the front roller bearing inner race to the end face of the ST.

      ST 499575400 GAUGE 

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   10. 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: Front roller bearing width

   B: Rear roller bearing width

   C: Spacer width

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

   E: Depth from end face of front roller bearing inner race to end face of ST

   15 mm (0.591 in): Thickness of ST

   T: Drive pinion washer thickness

   0±0.0125 mm (0±0.0005 in): Clearance

   Drive pinion washer
   Part No.	Thickness mm (in)
   38336AA750	0.150 (0.0059)
   38336AA760	0.175 (0.0069)

   Drive pinion washer
   Part No.	Thickness mm (in)
   38336AA770	0.200 (0.0079)
   38336AA780	0.225 (0.0089)
   38336AA790	0.250 (0.0098)
   38336AA800	0.275 (0.0108)
   38336AA810	0.300 (0.0118)
   38336AA820	0.400 (0.0157)

4. Measure and record the drive pinion shim thickness to be reused. If it is not reusable, select a drive pinion shim.
   1. Using a high precision round bar, measure the height "G" from transmission case mating surface of converter case to the top end of the round bar. Also measure the diameter "M" of the round bar and record it.

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   2. Using the following formula, calculate height "A1" from the transmission case mating surface of converter case to the lower edge of differential side retainer hole.

      A1 mm = G - M

      [A1 in = G - M]

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

      M: Diameter of round bar

   3. Measure the inner diameter "R" of the differential side retainer hole of the converter case.
      NOTE: Perform the measurement on the contact surface of the bearing outer race.

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   4. Using the following formula, calculate the radius "A2" of the differential side retainer hole.

      A2 mm = R/2

      [A2 in = R/2]

      R: Inner diameter of differential side retainer hole of converter case

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

      A mm = A1 + A2

      [A in = A1 + A2]

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

      Preparation tool: 

      ST: GAUGE (499575400)

      B mm = B1 - 15

      [B in = B1 - 0.591]

      B1: Depth from ST to drive pinion retainer mating surface

      15 mm (0.591 in): Thickness of ST

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   7. Using following formula, select one to three drive pinion washers.

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

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

   A: Distance from the transmission case mating surface of converter case to the center of differential

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

   E: Depth from end face of front roller bearing inner race to the end face of ST, measured in step (9) of "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

   Drive pinion shim
   Part No.	Thickness mm (in)
   31451AA320	0.150 (0.0059)
   31451AA330	0.175 (0.0069)
   31451AA340	0.200 (0.0079)
   31451AA350	0.225 (0.0089)
   31451AA360	0.250 (0.0098)
   31451AA370	0.275 (0.0108)

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5. Install the drive pinion shim that is reused for the drive pinion shaft.
6. Using the ST1 and ST2, press-fit the inner race to the drive pinion shaft.

   ST1 899580100 INSTALLER 

   ST2 927130000 EXTENSION DRIVE SHAFT 

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

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8. Install the selected drive pinion washer.

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9. Insert the drive pinion shaft into the drive pinion retainer.
   CAUTION: Be careful not to damage the oil seal.
10. Install the inner bearing and lock nut.
    NOTE:

    • Use a new lock nut.
    • Apply differential gear oil to the threaded portion of the drive pinion shaft.

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11. Using the ST, tighten the lock nut to the specified torque so that the starting torque of the drive pinion shaft is within the specified range.
    CAUTION: Before inspecting the starting torque, apply differential gear oil to roller of bearing and rotate the bearing several times.
    NOTE:

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

    Starting torque: 

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

    ST1 499787500 ADAPTER 

    ST2 499787700 WRENCH 

    ST3 498937110 HOLDER 

    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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12. Install the drive pinion retainer to the converter case, and check the backlash and tooth contact. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR580)>Drive Pinion Shaft Assembly>ADJUSTMENT . Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR580)>Front Differential Assembly>ADJUSTMENT .
13. Remove the drive pinion retainer from converter case. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR580)>Drive Pinion Shaft Assembly>REMOVAL .
14. Remove the drive pinion spacer from the drive pinion shaft. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR580)>Drive Pinion Shaft Assembly>DISASSEMBLY .
15. Install the O-ring to the drive pinion shaft.
    NOTE:

    • Use new O-rings.
    • Apply CVTF to the O-rings.

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16. Install the drive pinion spacer to the drive pinion shaft.

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17. Install the drive pinion washer.

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18. Insert the drive pinion shaft into the drive pinion retainer.
    CAUTION: Be careful not to damage the oil seal.

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19. Install the inner bearing and lock nut.
    NOTE: Apply differential gear oil to the threaded portion of the drive pinion shaft.

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20. Using the ST, tighten the lock nut to the specified torque so that the starting torque of the drive pinion shaft is within the specified range.
    CAUTION: Before inspecting the starting torque, apply differential gear oil to roller of bearing and rotate the bearing several times.
    NOTE:

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

    Starting torque: 

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

    ST1 499787500 ADAPTER 

    ST2 499787700 WRENCH 

    ST3 498937110 HOLDER 

    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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21. Crimp the lock nut in 2 locations.
22. Using the ST, install the plug.

ST1 499755602 PRESS SNAP RING 

ST2 398177700 INSTALLER 

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