Repair Procedures

Replacement

1. Fill the gear oil.

Specified lubricant:
Hypoid gear oil, MS 517-15 (API GL-5, SAE 75W/90)
Oil quantity: Fill the reservoir to the plug hold (About 1.4L ± 0.05L)




2. Remove the rear driveshaft
3. Remove the propeller shaft assembly
4. Loosen the differential carrier assembly mount bolts and than remove the differential assembly(A)

Tightening torque :
80 - 100 N.m (8.0 - 10.0 kgf.m, 57.8 - 72.3 lb-ft)








5. Installation is the reverse order of removal.

Disassembly

Rear differential carrier
1. Fill the gear oil.




2. Loosen the mount bolts and than remove the cover.




3. Mark as below before removing the differential assembly not to be changed with the left/right side of bearing cap.




4. Loosen the bearing cap bolts and than bearing cap.




5. Disassembly the differential assembly.




6. Mark as below removing the differential assembly not to be changed with the left/right side of bearing race.




Diff assembly Disassembly
1. Remove the bearing not to be damaged after setting the bearing remover at the discape hole.




2. Mark as blow removing the bearing no to be changed with the left/right side of bearing.




3. Loosen the ring gear bolt and than remove the drive gear.




4. Disconnect the lock pin.




5. Disconnect the diff shaft.




6. Disassembly the diff shaft/diff side gear/diff pinion gear/washer as below by putting a finger into the hole of diff shaft.




Pinion assembly disassembly
1. Loosen the pinion locking nut.




2. Remove the flange/pinion gear/pinion outer bearing by compressing the pinion gear with the pressing machine.




3. Remove the pinion inner bearing using the pinion gear press.




4. Remove the pinion oil seal.




5. Remove the right /left diff oil seal.






Inspection

1. Check the tooth contact pattern.






NOTE:
1. Tooth contact pattern is a method for judging the result of the adjustment of drive pinion height and final drive gear backlash. The adjustment of drive pinion height and final drive gear backlash should be repeated until the tooth contact patterns are similar to the standard tooth contact pattern.
2. When you cannot obtain a correct pattern, the drive gear and drive pinion have exceeded their limits. Both gears should be replaced as a set.

Reassembly

Pinion assembly
1. Press the inner/outer bearing race.




2. Select the pinion gear adjust shim and install it to the pingo gear. And then press the inner bearing.




3. Install the bearing spacer.





CAUTION:
Will have to use from new spacer.

4. Press the installed pinion assembly to carrier with outer bearing in the illustration.





NOTE:
Will have to be below pressure 5 ton.

5. Press the pinion oil seal.




6. Press the companion flange.




7. Install the pinion locking nut to make that the bearing free road is standard.

Tightening torque :
112.7 - 161.8 N.m (11.5 - 16.5 kgf.m, 83.1 - 119.3 lb-ft)




Differential case
1. Fix the diff assembly with both hands and install it to the differential carrier.




2. Instart the left/right diff shim between the diff side bearing and carrier. And then install the bearing cap with marks.




3. Adjust the diff shim.

Standard:0.10 - 0.15mm





NOTE:
Thickness of the diff shim need to adjusted if backrash is small. Lessen the thickness of the left side diff shim. By contraries enlarge the thickness of the right side diff shim that much.

4. Measures the free road.

Standard : Pinion free road : 1.9 - 4.9(0.2 - 0.5, 1.4 - 3.6)




5. Applies a sealant in the carrier.




6. Install the differential cover.

Tightening torque Nm (kgf.m, lb-ft) :
39.2 - 49.0 N.m (4.0 - 5.0 kgf.m, 28.9 - 39.1 lb-ft)




7. Install the diff oil seal.




8. Install the drain plug and pinier plug.

Pillar plug: 4 - 6 kgf.m
Drain plug: 5 - 7 kgf.m




9. Install the air breather.

Tightening torque :
9.8 - 19.6 N.m (1.0 - 2.0 kgf.m, 7.2 - 14.4 lb-ft)