Assembly
ADJUSTMENT OF DIFFERENTIAL CASEThrust Washer Selection
1. Install side gears, pinion mate gears, thrust washers into differential case.
2. Fit pinion mate shaft to differential case so that it meets lock pin holes.
3. Adjust clearance between rear face of side gear and thrust washer by selecting side gear thrust washer. Refer to "AVAILABLE SIDE GEAR THRUST WASHERS".
Use two feeler gauges to prevent leaning of side gear as showing, figure.
Clearance between side gear thrust washer and differential case: 0.20 mm (0.0079 inch) less
SIDE BEARING PRELOAD
A selection of carrier side bearing adjusting washers 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. Insert left and right side bearing adjusting washers in place between side bearings and carrier.
4. Install the side bearing caps in their correct locations and torque the bearing cap retaining bolts.
Torque: 88 - 98 Nm (9.0 - 9.9 kgm, 65 - 72 ft. lbs.)
5. Turn the carrier several times to seat the bearings.
6. 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 lb) of pulling force at the ring gear bolt
7. 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.
8. Record the total amount of washer thickness required for the correct carrier side bearing preload.
9. Remove the carrier from the final drive housing. Save the selected washers for later use during the assembly of the final drive unit.
Tool number: HT72400000
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 pinion preload shim selector Tool, J34309.
^ Pinion front bearing; make sure the J34309-3 pinion front bearing seat is secured tightly against the J34309-2 gauge anvil. Then turn the pinion front bearing pilot, J34309-5, to secure the bearing in its proper position.
^ Rear pinion bearing; the pinion rear bearing pilot, J34309-8, is used to center the pinion rear bearing only. The pinion rear bearing locking seat, J34309-4, is used to lock the bearing to the assembly.
^ Installation of J34309-9 and J34309-16; place a suitable 2.5 mm (0.098 inch) thick plain washer between J34309-9 and J34309-16. Both surfaces of J34309-9 and J34309-16 must be parallel with a clearance of 2.5 mm (0.098 inch).
3. Install the pinion rear bearing inner race 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 race 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 J34309-2 gauge anvil using torque wrench J-25765A.
Turning torque specification: 1.0 - 1.3 Nm (0.11 - 0.13 kg-m, 9 - 11 inch lbs.)
7. Place the J34309-11 "R200A" pinion height adapter onto the gauge plate and tighten it by hand.
CAUTION: Make sure all machined surfaces are clean.
Pinion Height Adjusting Washer Selection
1. Now, position the side bearing discs, J25269-4, and arbor firmly into the side bearing bores. Install the 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 J34309-11 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 drive pinion. The first one refers to the drive 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 Drive pinion height adjusting washer as follows. Refer to "AVAILABLE PINION HEIGHT ADJUSTING WASHERS".
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.
Ring 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.
ASSEMBLY OF DIFFERENTIAL CASE ASSEMBLY
1. Install pinion mate shaft lock pin with a punch. Make sure lock pin is flush with case.
2. Place differential case on ring gear.
3. Apply genuine medium strength locking sealant or equivalent. Refer to "RECOMMENDED FLUIDS AND LUBRICANTS" to ring gear bolts, and install them.
4. Press-fit side bearing inner race on differential case with Tool.
Tool number
A: KV38100300 (J25523)
B: ST33061000 (J18107-2)
INSTALLATION OF DRIVE PINION ASSEMBLY
1. Press-fit front and rear bearing outer races with Tools.
Tool number
A: Suitable tool
B: ST30611000 (J25742-1)
C: ST30613000 (J25742-3)
2. Select pinion height adjusting washer. Refer to "AVAILABLE PINION HEIGHT ADJUSTING WASHERS".
3. Install selected pinion height adjusting washer in drive pinion. Using press and Tool, press-fit pinion rear bearing inner race into it.
Tool number: ST30901000
4. 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.
5. Install front oil seal with Tool. Refer to "Removal and Installation".
Tool number: ST30720000 (J25405)
6. Install companion flange, and tighten pinion nut to minimum. Ascertain that threaded portion of drive pinion and drive pinion nut are free from oil or grease.
Tool number KV40104000
CAUTION: The drive pinion nut is not reusable. Never reuse drive pinion nut.
7. Tighten the drive pinion nut by very small degrees until the specified preload in achieved, when checking the preload, turn drive pinion in both directions several times.
Tool number: ST3127S000 (See J25765-A)
Pinion bearing preload: 2.65 - 3.23 Nm (0.27 - 0.32 kg-m, 24 - 28 inch lbs.)
^ If pinion bearing preload is too small, tighten the Drive pinion nut more.
^ If pinion bearing preload is too great, replace pinion bearing adjusting spacer.
INSTALLATION OF DIFFERENTIAL CASE ASSEMBLY
1. Select side bearing adjusting washer.
Refer to "SIDE BEARING ADJUSTING WASHERS".
2. Install differential case assembly with side bearing outer races into gear carrier.
3. Insert left and right side bearing adjusting washers in place between side bearings and carrier.
4. Align mark on bearing cap with that on gear carrier and install bearing cap on gear carrier.
Torque: 88 - 98 Nm (9.0 - 9.9 kg-m, 65 - 72 ft. lbs.)
5. Install side oil seal. Refer to "Removal and Installation".
Tool number: KV38100200 (J26233)
6. Measure ring gear-to-drive pinion backlash with a dial indicator at several point.
Ring gear backlash: 0.10 - 0.15 mm (0.0039 - 0.0059 inch) less
^ If backlash is too small, adjustment of washer thickness is required. Decrease thickness of left shim and increase thickness of right by the same amount. If backlash is too great, reverse the above procedure.
Never change the total amount of washers as it will change the bearing preload.
7. Check total preload with Tool.
Tool number: ST3127S000 (See J25765-A)
When checking preload, turn drive pinion in both directions several times to seat bearing rollers correctly
Total preload: 2.84 - 3.75 Nm (0.29 - 0.38 kg-m, 26 - 33 inch lbs.)
^ If preload is too great, remove the same amount of washer to each side.
^ If preload is too small, add the same amount of washer to each side.
Never add or remove a different number of washers for each side. Difference in number of washers will change ring gear to drive pinion backlash.
8. 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.
9. Check runout of ring gear with a dial indicator.
Runout limit: 0.05 mm (0.0020 inch) less
10. Check tooth contact.
Refer to "TOOTH CONTACT"
11. Install rear cover. Apply liquid sealant to rear cover side and install gear carrier.