Drive Pinion
DRIVE PINIONDLN-197 Exploded View:
Disassembly
1. Remove differential case assembly.
2. Remove drive pinion lock nut with the 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 on the final drive companion flange indicates he maximum vertical runout position.
When replacing companion flange, matching mark is not necessary.
4. Remove companion flange using the suitable pullers.
5. Press drive pinion assembly out of gear carrier.
CAUTION: Never drop drive pinion assembly.
6. Remove front oil seal.
7. Remove side oil seal.
8. Remove pinion front bearing inner race.
9. Remove collapsible spacer.
10. Remove pinion rear bearing inner race and pinion height adjusting washer with the replacer (A) (commercial service tool).
11. Tap pinion front/rear bearing outer races uniformly using a brass rod or equivalent to remove them.
CAUTION: Never damage gear carrier.
Assembly
1. Install front bearing outer race (1) and rear bearing outer race (2) using drifts.
A: Drift [SST: ST30720000 (J-25405)]
B: Drift [SST: KV40105230 ( - )]
C: Drift bar [SST: ST3061100 (J-25742-1)]
D: Drift [SST: ST30613000 (J-25742-3)]
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. Select drive pinion height adjusting washer.
3. Install selected drive pinion height adjusting washer (2) to drive pinion. Press pinion rear bearing inner race (1) to it, using drift (A) [SST: ST3090100 (J-26010-01)].
CAUTION:
^ Be careful of the direction of pinion height adjusting washer. (Assemble as shown in the figure.)
^ Never reuse pinion rear bearing inner race.
4. Assemble collapsible spacer to drive pinion.
CAUTION: Never reuse collapsible spacer.
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. Using the drift (A) [SST: ST30720000 (J-25405)], install front oil seal as shown in figure.
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.
9. 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.
10. Apply anti-corrosion oil to the thread and seat of drive pinion lock nut, and temporarily tighten drive pinion lock nut to drive pinion.
CAUTION: Never reuse drive pinion lock nut.
11. Adjust to the drive pinion lock nut tightening torque and pinion bearing preload torque.
A: Preload gauge [SST: ST3127S000 (J-25765-A)]
Standard
Pinion bearing preload: Refer to DLN-207, "Preload Torque". Preload Torque
CAUTION:
^ Adjust to the lower limit of the drive pinion lock nut tightening torque first.
^ If the preload torque exceeds the specified value, replace collapsible spacer and tighten it again to adjust. Never loosen drive pinion lock nut to adjust the preload torque.
^ After adjustment, rotate drive pinion back and forth 2 to 3 times to check for unusual noise, rotation malfunction, and other malfunctions.
12. Install differential case assembly.
CAUTION: Never install rear cover at this timing.
13. 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.
14. Check total preload torque.
15. Install rear cover.
Adjustment
PINION GEAR HEIGHT
1. Make sure all parts are clean and that the bearings are well lubricated.
2. Assemble the pinion gear bearings into the differential shim selector tool [SST: - (J-34309)].
^ Pinion front bearing; make sure the J-34309-3 pinion front bearing seat is secured tightly against the J-34309-2 gauge anvil. Then turn the pinion front bearing pilot, J-34309-5, to secure the bearing in its proper position.
^ Pinion rear bearing; the pinion rear bearing pilot, J-34309-8, is used to center the pinion rear bearing only The pinion rear bearing locking seat, J-34309-4, is used to lock the bearing to the assembly.
^ Installation of J-34309-9 and J-34309-16; place a suitable 2.5 mm (0.098 in) thick plain washer between J-34309-9 and J-34309-16. Both surfaces of J-34309-9 and J-34309-16 must be parallel with a clearance of 2.5 mm (0.098 in).
3. Install the pinion rear bearing inner race into gear carrier. Then place the pinion preload shim selector tool, J-34309-1, gauge screw assembly.
4. Assemble the pinion front bearing inner race and the J-34309-2 gauge anvil. Assemble them together with the J-34309-1 gauge screw in gear carrier. Make sure that the pinion height gauge plate, J-34309-16, turns a full 360 degrees. Tighten the two sections together by hand.
5. Turn the assembly several times to seat the bearings.
6. Measure the turning torque at the end of the J-34309-2 gauge anvil using preload gauge [SST: ST3127S000 (J-25765-A)].
Standard
Turning torque specification: 1.0 - 1.3 Nm (0.11 - 0.13 kg-m, 9 - 11 in-lb)
7. Place the J-34309-11 "R200A" pinion height adapter onto the gauge plate and tighten it by hand.
CAUTION: Make sure all machined surfaces are clean.
8. Position the side bearing discs, J-25269-4, and arbor firmly into the side bearing bores. Install the bearing caps and tighten bearing cap mounting bolts to the specified torque. Refer to "AWD: Exploded View".
9. Select the correct standard pinion height adjusting washer thickness. Select by using a standard gauge of 3 mm (0.12 in) and J-34309-101 feeler gauge. Measure the distance between the J-34309-11 pinion height adapter including the standard gauge and the arbor.
10. Write down exact measurement (the value of feeler gauge).
11. Correct the pinion height washer size by referring to the "pinion head number".
There are two numbers painted on the drive pinion. The first one refers to the drive pinion and drive gear as a matched set. This number should be the same as the number on the drive gear. The second number is the "pinion head height number". It refers to the ideal pinion height from standard for quietest operation. Use the following chart to determine the correct pinion height washer.
12. Select the correct pinion height adjusting washer.
13. Remove the J-34309 differential shim selector tool from the final drive housing. Then disassemble to retrieve the pinion bearings.
COMPANION FLANGE RUNOUT
1. Fit a test indicator to the inner side of companion flange (socket diameter).
2. Rotate companion flange to check for runout.
Limit
Companion flange runout: Refer to DLN-208, "Companion Flange Runout (AWD)". Companion Flange Runout
3. 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.