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Document Text Contents
Page 1

1. Manual Transmission and Differential

Item

Model

AWD

2200 cc 2500 cc
Type 5-forward speeds with synchromesh and 1-reverse

Transmission gear ratio

1st 3.545
2nd 2.111
3rd 1.448
4th 1.088
5th 0.780
Reverse 3.333

Front reduction
gear

Final
Type of gear Hypoid
Gear ratio 3.900 4.111

Rear reduction
gear

Transfer
Type of gear Helical
Gear ratio 1.000

Final
Type of gear Hypoid
Gear ratio 3.900 4.111

Front differential Type and number of gear Straight bevel gear (Bevel pinion: 2, Bevel gear: 2)
Center differen-
tial

Type and number of gear
Straight bevel gear (Bevel pinion: 2, Bevel gear: 2 and viscous cou-

pling)
Transmission gear oil GL-5
Transmission oil capacity 3.5 • (3.7 US qt, 3.1 Imp qt)

2. Transmission Gear Oil
Recommended oil

B1H0024

3. Transmission Case
Assembly
Drive pinion shim adjustment

Drive pinion shim

Part No.
Thickness
mm (in)

Part No.
Thickness
mm (in)

32295AA031
0.150

(0.0059)
32295AA071

0.250
(0.0098)

32295AA041
0.175

(0.0069)
32295AA081

0.275
(0.0108)

32295AA051
0.200

(0.0079)
32295AA091

0.300
(0.0118)

32295AA061
0.225

(0.0089)
32295AA101

0.500
(0.0197)

Hypoid gear backlash
0.13 Ð 0.18 mm (0.0051 Ð 0.0071 in)

Selection of main shaft rear plate

Main shaft rear plate

Dimension ªAº mm (in) Part No. Mark
4.00 Ð 4.13 (0.1575 Ð 0.1626) 32294AA041 1
3.87 Ð 3.99 (0.1524 Ð 0.1571) 32294AA051 2

2

3-1 [S100] SPECIFICATIONS AND SERVICE DATA
1. Manual Transmission and Differential

Page 2

4. Drive Pinion Assembly
Preload adjustment of thrust bearing

Starting torque
0.3 — 0.8 N·m
(0.03 — 0.08 kg-m, 0.2 — 0.6 ft-lb)

Adjusting washer No. 1

Part No. Thickness mm (in)
803025051 3.925 (0.1545)
803025052 3.950 (0.1555)
803025053 3.975 (0.1565)
803025054 4.000 (0.1575)
803025055 4.025 (0.1585)
803025056 4.050 (0.1594)
803025057 4.075 (0.1604)

Adjusting washer No. 2

Part No. Thickness mm (in)
803025059 3.850 (0.1516)
803025054 4.000 (0.1575)
803025058 4.150 (0.1634)

5. Reverse Idler Gear
Adjustment of reverse idler gear position
Reverse idler gear to transmission case (LH) wall
clearance

6.0 — 7.5 mm (0.236 — 0.295 in)

Reverse shifter lever

Part No. Mark Remarks
32820AA070 7 Further from case wall
32820AA080 8 Standard
32820AA090 9 Closer to the case wall

After installing a suitable reverse shifter lever,
adjust reverse idler gear to transmission case wall
clearance to within 0 to 0.5 mm (0 to 0.020 in)
using washers.

Washer (20.5 × 26 × t)

Part No.
Thickness
mm (in)

Part No.
Thickness
mm (in)

803020151 0.4 (0.016) 803020154 1.9 (0.075)
803020152 1.1 (0.043) 803020155 2.3 (0.091)
803020153 1.5 (0.059)

3

[S500] 3-1SPECIFICATIONS AND SERVICE DATA
5. Reverse Idler Gear

Page 111

34) Remove parking support.

B3M1088A

4. TORQUE CONVERTER CLUTCH CASE
SECTION

1) Wrap the axle shaft serration with vinyl tape.

G3M0368

2) Remove the differential side retainer with ST.

CAUTION:
Hold the differential case assembly by hand to
avoid damaging retainer mounting hole of the
torque converter clutch case and speedometer
gears.

ST 499787000 WRENCH ASSY
3) Extract the axle shaft with ST1 and ST2.

CAUTION:
Do not reuse the circlip.

ST1 499095500 REMOVER
ST2 499247300 INSTALLER

G3M0956

4) Remove the differential case assembly.

CAUTION:
I Remove the seal pipe if it is attached. (Reus-
ing is not allowed.)
I Be careful not to damage the retainer mount-
ing hole of the torque converter clutch case
and the speedometer gears.

G3M0370

5. EXTENSION SECTION

1) Take out the transfer clutch by lightly tapping
the end of the rear drive shaft.

CAUTION:
Be careful not to damage the oil seal in the
extension.

B3M1089A

2) Remove the transfer pipe.

CAUTION:
Be careful not to bend the pipe.

B3M1090A

59

[W12B5] 3-2SERVICE PROCEDURE
12. Overall Transmission

Page 112

C: ASSEMBLY OF OVERALL
TRANSMISSION
1. TORQUE CONVERTER CLUTCH CASE
SECTION
1) Check the appearance of each component and
clean.

CAUTION:
Make sure each part is free of harmful cuts,
damage and other faults.

2) Force-fit the oil seal to the torque converter
clutch case with ST.
ST 398437700 DRIFT

G3M0379

3) Install the differential assembly to the case,
paying special attention not to damage the inside
of the case (particularly, the differential side
retainer contact surface).

G3M0380

4) Install the circlip to the axle shaft, insert the
shaft into the differential assembly, and tap it into
position with a plastic hammer.

CAUTION:
I If no play is felt, check whether the shaft is
fully inserted. If shaft insertion is correct,
replace the axle shaft.
I Be sure to use a new circlip.

Thrust play:
0.3 — 0.5 mm (0.012 — 0.020 in)

5) Wrap vinyl tape around the splined portion of
the axle shaft.

G3M0368

6) Install the oil seal and outer race (taper roller
bearing) to the differential side retainer. Then
screw in the retainer and the O-ring after coating
the threads with oil.

CAUTION:
I Pay attention not to damage the oil seal lips.
I Do not confuse the RH and LH oil seals.
I Keep the O-ring removed from the retainer.

7) Using the ST, screw in the retainer until light
contact is felt.

NOTE:
Screw in the RH side slightly deeper than the LH
side.

ST 499787000 WRENCH ASSY

B3M0352A

8) Hypoid gear backlash adjustment and tooth
contact check

(1) Assemble the drive pinion assembly to the
oil pump housing.

CAUTION:
I Be careful not to bend the shims.
I Be careful not to force the pinion against the
housing bore.

60

3-2 [W12C1] SERVICE PROCEDURE
12. Overall Transmission

Page 221

1. Propeller Shaft
NOTE:
Vibration while cruising may be caused by an
unbalanced tire, improper tire inflation pressure,
improper wheel alignment, etc.

Symptom Possible cause Remedy
1. Vibration of propeller shaft
NOTE:
Vibration is caused by propeller shaft
during operation and is transferred to
vehicle body. Generally vibration
increase in proportion to vehicle speed.

(1) Worn or damaged universal joint. Replace.
(2) Unbalanced propeller shaft due to
bend or dent.

Replace.

(3) Loose installation of propeller shaft. Retighten.
(4) Worn or damaged center bearing and
damaged center mounting rubber.

Replace.

2. Tapping when starting and noise
while cruising, caused by propeller
shaft.

(1) Worn or damaged universal joint. Replace.
(2) Worn spline of sleeve yoke. Replace.
(3) Loose installation of propeller shaft. Retighten.
(4) Loose installation of joint. Replace.
(5) Worn or damaged center bearing and
damaged center mounting rubber.

Replace.

2. Rear Differential
Symptom or trouble Possible cause Remedy

1. Oil leakage (1) Worn, scratched, or incorrectly
seated front or side oil seal. Scored,
battered, or excessively worn sliding sur-
face of companion flange.

Repair or replace.

(2) Clogged or damaged air breather. Clean, repair or replace.
(3) Loose bolts on differential spindle or
side retainer, or incorrectly fitted O-ring.

Tighten bolts to specified torque.
Replace O-ring.

(4) Loose rear cover attaching bolts or
damaged gasket.

Tighten bolts to specified torque.
Replace gasket and apply liquid packing.

(5) Loose oil filler or drain plug. Retighten and apply liquid packing.
(6) Wear, damage or incorrectly fitting for
spindle, side retainer and oil seal.

Repair or replace.

2. Seizure
NOTE:
Seized or damaged parts should be
replaced, and also other parts should be
thoroughly checked for any defect and
should be repaired or replaced as
required.

(1) Insufficient backlash for hypoid gear. Readjust or replace.

(2) Excessive preload for side, rear, or
front bearing.

Readjust or replace.

(3) Insufficient or improper oil used. Replace seized part and fill with speci-
fied oil to specified level.

3. Damage
NOTE:
Damaged parts should be replaced, and
also other parts should be thoroughly
checked for any defect and should be
repaired or replaced as required.

(1) Improper backlash for hypoid gear. Replace.
(2) Insufficient or excessive preload for
side, rear, or front bearing.

Readjust or replace.

(3) Excessive backlash for differential
gear.

Replace gear or thrust washer.

(4) Loose bolts and nuts such as crown
gear bolt.

Retighten.

(5) Damage due to overloading. Replace.
4. Noises when starting or shifting
gears
NOTE:
Noises may be caused by differential
assembly, universal joint, wheel bearing,
etc. Find out what is actually making
noise before disassembly.

(1) Excessive backlash for hypoid gear. Readjust.
(2) Excessive backlash for differential
gear.

Replace gear or thrust washer.

(3) Insufficient preload for front or rear
bearing.

Readjust.

(4) Loose drive pinion nut. Tighten to specified torque.
(5) Loose bolts and nuts such as side
bearing retainer attaching bolt.

Tighten to specified torque.

54

3-4 [K100] DIAGNOSTICS
1. Propeller Shaft

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