Assembly
Assembly1. Place differential case on ring gear.
2. Apply locking sealant (Three Bond TB1324 Part No.999 -AM005P or equivalent) to ring gear bolts, and install them.
Tighten bolts in a cries-cross fashion, lightly tapping bolt head with a hammer.
3. Press-fit side bearing inner cones on differential case with Tool.
Tool number:
A KV38100300 (-125523)
B ST33061000 (-18107-2)
4. Press-fit front and rear bearing outer races with Tools.
Tool number:
A Suitable tool
B ST30611000 (-125742-1)
C ST30613000 (-125742-3)
5. Select pinion bearing adjusting washer and drive pinion bearing spacer.
6. Install selected drive pinion height adjusting washer in drive pinion. Using press and Tool, press-fit pinion rear bearing inner cone into it.
Tool number: ST30901000 (-)
7. Place pinion front bearing inner cone in final drive housing.
8. Set drive pinion assembly (as shown in figure) in differential carrier and install drive pinion, with press and suitable tool.
Stop when drive pinion touches bearing.
Apply multi-purpose grease to pinion rear bearing inner race and pinion front bearing inner race.
9. Install front oil seal with Tool.
Tool number: KV38100500 ( - )
10. Install companion flange, and tighten pinion nut to specified torque with Tool. Ascertain that threaded portion of drive pinion and pinion nut are free from oil or grease.
Tool number: KV38104700 (J34311)
11. Turn drive pinion in both directions several times, and measure pinion bearing preload.
Tool number: ST3127SOOO (See J25765-A)
Pinion bearing preload: 1.8 - 2.3 Nm (18 - 24 kg-cm, 16 - 20 inch lbs.)
When pinion bearing preload is outside specifications, replacement is required for pinion bearing adjusting washer and spacer. Replace with those of different thickness.
12. Select side bearing adjusting washer.
13. Install differential case assembly with side bearing outer races into gear carrier.
14. Insert left and right side bearing adjusting washers in place between side bearings and carrier.
15. Drive in side bearing spacer with Tool.
Tool number: KV38100600 (J25267)
16. Align mark on bearing cap with that on gear carrier and install bearing cap on gear carrier.
17. Install side oil seal.
Tool number:KV38100200 (J26233)
18. Measure ring gear-to-drive pinion backlash with a dial indicator.
Ring gear backlash: 0.10 - 0.15 mm (0.0039 - 0.0059 inch)
- If backlash is too small, adjustment of shim thickness is required. Decrease thickness of left shim and increase thickness of right shim by the same amount. If backlash is too great, reverse the above procedure. Never change the total amount of shims as it will change the bearing preload.
19. Check total preload with Tool.
Tool number: ST3127SOOO (See J25765-A)
When checking preload, turn drive pinion in both directions several times to seat bearing rollers correctly.
Total preload: 2.0 - 2.8 Nm (20 - 29 kg-cm, 18 - 25 inch lbs.)
- If preload is too great, remove the same amount of shim to each side.
- If preload is too small, add the same amount of shim to each side.
Never add or remove a different number of shims for each side. Difference in number of shims will change ring gear to drive pinion backlash.
20. Recheck ring gear to drive pinion backlash. Increase or decrease in thickness of shims will cause change to ring gear to pinion backlash.
- Check whether the backlash varies excessively in different places. Foreign matter may be caught between the ring gear and the differential case causing the trouble.
- The backlash can vary greatly even when the ring gear runout is within a specified range. In that case, replace the hypoid gear set or differential case.
21. Check runout of ring gear with a dial indicator.
Runout limit: 0.05 mm (0.0020 inch)
22. Check tooth contact.
23. Install rear cover and gasket.