Adjustment
AdjustmentDIFFERENTIAL CASE
Thrust Washer Selection
Whenever side gears or pinion mate gears are replaced, select suitable thrust washers as follows:
1. Clean side gears and pinion mate gears using white gasoline.
2. Before assembling gears, apply hypoid gear oil to frictional surfaces.
3. Install the previously removed thrust washer on right side gear. On left side gear, install a suitable thrust washer. Temporarily tighten differential cases using two screws.
4. Position differential assembly so that right side gear is on the upper side. Place two feeler gauges of 0.03 mm (0.0012 inch) thickness between right side gear and thrust washer as shown.
- Do not place feeler gauge at groove side of differential case.
5. Also place a 0.03 mm (0.0012 inch) additional feeler gauge between right side gear and thrust washer so that it is positioned diagonal to (180� apart from) the feeler gauge described previously.
6. Rotate right side gear with a suitable tool attached to splines. If hard to rotate, replace thrust washer on left side gear with a thinner one.
7. Replace both 0.03 mm (0.0012 inch) feeler gauges with 0.10 mm (0.0039 inch) gauges. At this point, make sure right side gear does not rotate. If it rotates, replace thrust washer on left side gear with a thicker one to prevent rotation.
8. As explained in above example, select suitable thrust washers to ensure that:
a. Both side gears rotate. [0.03 mm (0.0012 inch) feeler gauges are used in this case.]
b. Side gear is held stationary. [0.10 mm (0.0039 inch) gauges are used in this case.]
- For quiet and reliable final drive operation, the following five adjustments must be made correctly.
1. Side bearing preload
2. Pinion gear height
3. Pinion bearing preload
4. Ring gear to pinion backlash.
5. Ring and pinion gear tooth contact pattern
SIDE BEARING PRELOAD
- A selection of carrier side bearing preload shims is required for successful completion of this procedure.
1. Make sure all parts are clean. Also, make sure the bearings are well lubricated with light oil or DEXRON TM type automatic transmission fluid.
2. Place the differential carrier, with side bearings and bearing races installed, into the final drive housing.
3. Put the side bearing spacer in place on the ring gear end of the carrier.
4. Use the J25267 side bearing spacer drift. Place original carrier side bearing preload shims on the carrier end, opposite the ring gear.
Tool number:KV38100600 (J25267)
5. Install the side bearing caps in their correct locations and torque the bearing cap retaining bolts.
Specification: 88 - 98 Nm (9 - 10 kgf-cm, 65 - 72 ft. lbs.)
6. Turn the carrier several times to seat the bearings.
7. Measure the turning torque of the carrier at the ring gear retaining bolts with a spring gauge, J-8129.
Specification: 34.2 - 39.2 N (3.5 - 4 kg, 7.7 - 8.8 lbs.) of pulling force at the ring gear bolt
8. If the turning torque is not within the specifications, correct the torque as follows:
- If the turning torque is less than the specified range, install washers of greater thickness.
- If the turning torque is greater than the specification, install thinner washers.
9. Record the total amount of washer thickness required for the correct carrier side bearing preload.
10. Remove the carrier from the final drive housing. Save the selected preload washers for later use during the assembly of the final drive unit.
Tool number: HT72400000 (-)
PINION GEAR HEIGHT AND PINION BEARING PRELOAD
1. Make sure all parts are clean and that the bearings are well lubricated.
2. Assemble the pinion gear bearings into the pinion preload shim selector Tool, J-34309.
- Front pinion bearing; make sure the J-34309-3 front pinion bearing seat is secured tightly against the J-34309-2 gauge anvil. Then turn the front pinion bearing pilot, J-34309-5, to secure the bearing in its proper position.
- Rear pinion bearing; the rear pinion bearing pilot, J-34309-8, is used to center the rear pinion bearing only. The rear pinion 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 inch) 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 inch).
3. Install the pinion rear bearing inner cone into the final drive housing. Then place the pinion preload shim selector Tool, J34309-1, gauge screw assembly.
4. Assemble the front pinion bearing inner cone and the J34309-2 gauge anvil. Assemble them together with the J34309-1 gauge screw in the final drive housing. Make sure that the pinion height gauge plate, J34309-16, will turn 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 torque wrench J-25765A.
Turning torque specification: 1.0 - 1.3 Nm (10 - 13 kg-cm, 8.7 - 11.3 inch lbs.)
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.
Pinion Bearing Preload Washer Selection
1. Place the solid pinion bearing spacer, small end first, over the J34309-2 gauge anvil. Seat the small end squarely against the tip of the J34309-1 gauge screw in the tool recessed portion.
2. Select the correct thickness of pinion bearing preload adjusting washer. Select by using a standard gauge of 3.5 mm (0.138 inch) and your J34309-101 feeler gauge. The exact measure you get with your gauges is the thickness of the adjusting washer required. Select the correct washer as follows.
Drive pinion bearing preload adjusting washer:
Refer to "SERVICE DATA" .
3. Set aside the selected correct pinion bearing preload adjusting washer. Use it when assembling the pinion gear and bearings into the final drive.
Pinion Height Adjusting Washer Selection
1. Now, position the side bearing discs, J-25269-4, and arbor firmly into the side bearing bores. Install the side bearing caps and tighten the cap bolts to proper torque.
2. Select the correct standard pinion height adjusting washer thickness. Select by using a standard gauge of 3 mm (0.12 inch) and your J34309-101 feeler gauge. Measure the distance between the J-34309-11 pinion height adapter including the standard gauge and the arbor.
3. Write down your exact measurement (the value of feeler gauge).
4. Correct the pinion height washer size by referring to the "pinion head number".
There are two numbers painted on the pinion gear. The first one refers to the pinion and ring gear as a matched set. This number should be the same as the number on the ring 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.
5. Select the correct pinion height washer as follows.
Drive pinion height adjusting washer.
Refer to "SERVICE DATA".
6. Remove the J34309 pinion preload shim selector Tool from the final drive housing. Then disassemble to retrieve the pinion bearings.
TOOTH CONTACT
Checking gear tooth contact pattern is necessary to verify correct relationship between ring gear and drive pinion.
Hypoid gears which are not positioned in proper arrangement may be noisy and/or have a short life. Check gear tooth contact pattern to obtain the best contact for low noise and long life,
1. Thoroughly clean ring gear and drive pinion teeth.
2. Lightly apply a mixture of powdered ferric oxide and oil or the equivalent. Apply it to 3 or 4 teeth of ring gear drive side.
3. Hold companion flange steady by hand and rotate the ring gear in both directions.