Drive Pinion
DRIVE PINIONDLN-125 Exploded View (Part 1):
DLN-125 Exploded View (Part 2):
Disassembly
1. Remove differential case assembly.
2. Remove drive pinion lock nut with a flange wrench.
3. Put matching mark (B) on the end of drive pinion. The matching ark should be in line with the matching mark (A) on companion flange (1).
CAUTION: For matching mark, use paint. Never damage companion flange and drive pinion.
NOTE: The matching mark (A) on the final drive companion flange (1) indicates the maximum vertical runout position.
When replacing companion flange, matching mark is not necessary.
4. Remove companion flange using the suitable puller.
5. Press drive pinion assembly out of gear carrier.
CAUTION: Never drop drive pinion assembly.
6. Remove front oil seal.
7. Remove pinion front bearing inner race.
8. Remove drive pinion bearing adjusting washer and drive pinion adjusting washer.
9. Remove pinion rear bearing inner race and pinion height adjusting washer with replacer (A) (commercial service tool).
10. Tap pinion front/rear bearing outer races uniformly a brass rod or equivalent to removed.
CAUTION: Never damage gear carrier.
Assembly
1. Install pinion front and rear bearing outer races using drift (A) [SST: ST37820000 ( - )].
CAUTION:
^ At first, using a hammer, tap bearing outer race until it becomes flat to gear carrier.
^ Never reuse pinion front and rear bearing outer race.
2. Temporarily install pinion height adjusting washer (1).
When hypoid gear set has been replaced
^ Select pinion height adjusting washer.
When hypoid gear set has been reused
^ Temporarily install the removed pinion height adjusting washer or same thickness washer to drive pinion.
3. Install selected pinion height adjusting washer (2) to drive pinion. Press pinion rear bearing inner race (1) to it, using drift (A) [SST: ST30032000 (J-26010-01)].
CAUTION:
^ Pay attention to the direction of pinion height adjusting washer. (Assemble as shown in the figure.)
^ Never reuse pinion rear bearing inner race.
4. Temporarily assemble removed drive pinion adjusting washer and drive pinion bearing adjusting washer or same thickness of them to drive pinion.
5. Apply gear oil to pinion rear bearing, and assemble drive pinion into gear carrier.
6. Apply gear oil to pinion front bearing, and assemble pinion front bearing inner race to drive pinion assembly.
CAUTION: Never reuse pinion front bearing inner race.
7. Using suitable spacer (A), press the pinion front bearing inner race to drive pinion as far as drive pinion nut can be tightened.
8. Adjust pinion bearing preload. If necessary, select the appropriate drive pinion adjusting washer and drive pinion bearing adjusting washer.
9. Using the drifts, install front oil seal as shown in figure.
A: Drift [SST: ST33400001 (J-26082)]
B: Drift [SST: KV38102510 ( - )]
CAUTION:
^ Never reuse oil seal.
^ When installing, never incline oil seal.
^ Apply multi-purpose grease onto oil seal lips, and gear oil onto the circumference of oil seal.
10. Install companion flange (1).
NOTE: When reusing drive pinion, align the matching mark (B) of drive pinion with the matching mark (A) of companion flange, and then install companion flange (1).
11. Apply anti-corrosion oil to the thread and seat of new drive pinion lock nut, and temporarily tighten drive pinion lock nut to drive pinion.
CAUTION: Never reuse drive pinion lock nut.
12. Tighten to drive pinion lock nut, while adjusting pinion bearing preload torque.
A: Preload gauge [SST: ST3127S000 (J-25765-A)]
Standard
Pinion bearing preload: Refer to DLN-133, "Preload Torque". Preload Torque
CAUTION:
^ Adjust to the lower limit of the drive pinion lock nut tightening torque first.
^ After adjustment, rotate drive pinion back and forth 2 to 3 times to check for unusual noise, rotation malfunction, and other malfunctions.
13. Install differential case assembly.
CAUTION: Never install carrier cover yet.
14. Check and adjust drive gear runout, tooth contact, drive gear to drive pinion backlash, and companion flange runout.
Recheck above items. Readjust the above description, if necessary.
15. Check total preload torque.
16. Install carrier cover.
PINION GEAR HEIGHT
If the hypoid gear set has been replaced, select the pinion height adjusting washer.
1. Use the formula below to calculate pinion height adjusting washer thickness.
Washer selection equation:
T = T0 + (t1 - t2)
T: Correct washer thickness
T0: Removed washer thickness
t1: Old drive pinion head letter "H x 0.01 ("H": machined tolerance 1/100 mm x 100)
t2: New drive pinion head letter "H x 0.01 ("H": machined tolerance 1/100 mm x 100)
Example:
T = 3.21 [(2 x 0.01) - (-1 x 0.01)] = 3.24
T0: 3.21
t1: +2
t2: -1
2. Select the proper pinion height adjusting washer.
If unable to find a washer of desired thickness, use a washer with thickness closest to the calculated value.
Example:
Calculated value... T = 3.22 mm
Used washer... T = 3.21 mm
PINION BEARING PRELOAD
Assemble the drive pinion parts if they are disassembled.
1. Make sure all parts are clean. Also, make sure the bearings are well lubricated with gear oil.
2. Install companion flange (1).
NOTE: When reusing drive pinion, align the matching mark (B) of drive pinion with the matching mark (A) of companion flange, and then install companion flange (1).
3. Temporarily tighten removed drive pinion lock nut to drive pinion.
NOTE: Use removed drive pinion lock nut only for the preload measurement.
4. Rotate drive pinion at least 20 times to check for smooth operation of the bearing.
5. Tighten to drive pinion lock nut, while adjust pinion bearing preload torque.
A: Preload gauge [SST: ST3127S000 (J-25765-A)]
Standard
Pinion bearing preload: Refer to DLN-133, "Preload Torque". Preload Torque
CAUTION:
^ Adjust to the lower limit of the drive pinion lock nut tightening torque first.
^ After adjustment, rotate drive pinion back and forth 2 to 3 times to check for unusual noise, rotation malfunction, and other malfunctions.
6. If the pinion bearing preload torque is outside the specification use a thicker/thinner drive pinion bearing adjusting washer and drive pinion adjusting washer to adjust.
When the preload torque is large:
Decrease the drive pinion bearing adjusting washer and drive pinion adjusting washer thickness. For select parts refer to parts information.
When the preload is small:
Increase the drive pinion bearing adjusting washer and drive pinion adjusting washer thickness. For select parts refer to parts information.
7. Remove companion flange, after adjustment.
COMPANION FLANGE RUNOUT
1. Fit a dial indicator onto the companion flange face (inner side of the propeller shaft mounting bolt holes).
2. Rotate companion flange to check for runout.
Limit
Companion flange runout: Refer to DLN-133, "Companion Flange Runout". Companion Flange Runout
3. Fit a test indicator to the inner side of companion flange (socket diameter).
4. Rotate companion flange to check for runout.
Limit
Companion flange runout: Refer to DLN-133, "Companion Flange Runout". Companion Flange Runout
5. If the runout value is outside the runout limit, follow the procedure below to adjust.
a. Check for runout while changing the phase between companion flange and drive pinion by 90° step, and search for the position where the runout is the minimum.
b. If the runout value is still outside of the limit after the phase has been changed, possible cause will be an assembly malfunction of drive pinion and pinion bearing and malfunction of pinion bearing. Check for these items and repair if necessary.
c. If the runout value is still outside of the limit after the check and repair, replace companion flange.
Inspection After Disassembly
DRIVE GEAR AND DRIVE PINION
^ Clean up the disassembled parts.
^ If the gear teeth never mesh or line-up correctly, determine the cause and adjust or replace as necessary.
^ If the gears are worn, cracked, damaged, pitted or chipped (by friction) noticeably, replace with new drive gear and drive pinion as a set.
BEARING
^ Clean up the disassembled parts.
^ If any chipped (by friction), pitted, worn, rusted or scratched marks, or unusual noise from the bearing is observed, replace as a bearing assembly (as a new set).
SIDE GEAR AND PINION MATE GEAR
^ Clean up the disassembled parts.
^ If any cracks or damage on the surface of the tooth is found, replace.
^ If any worn or chipped mark on the contact sides of the thrust washer is found, replace.
SIDE GEAR THRUST WASHER AND PINION MATE THRUST WASHER
^ Clean up the disassembled parts.
^ If it is chipped (by friction), damaged, or unusually worn, replace.
OIL SEAL
^ Whenever disassembled, replace.
^ If wear, deterioration of adherence (sealing force lips), or damage is detected on the lips, replace them.
DIFFERENTIAL CASE
^ Clean up the disassembled parts.
^ If any wear or crack on the contact sides of the differential case is found, replace.
COMPANION FLANGE
^ Clean up the disassembled parts.
^ If any chipped mark [about 0.1 mm, (0.004 in)] or other damage on the contact sides of the lips of the companion flange is found, replace.