Assembly
Image Symbols:
ASSEMBLY
Drive Pinion Assembly
1. Install front and rear bearing outer races using drifts.
Tool number
A: ST30720000 (J-25405)
B: KV40105230 ( - )
C: ST30611000 (J-25742-1)
D: ST30613000 (J-25742-3)
CAUTION:
^ At first, using a hammer, tap bearing outer race until it becomes flat to gear carrier.
^ Do not reuse pinion front and rear bearing outer race.
2. Select drive pinion height adjusting washer.
3. Install selected drive pinion height adjusting washer to drive pinion. Press pinion rear bearing inner race to it, using drift.
Tool number: ST30901000 (J-26010-01)
CAUTION:
^ Pay attention to the direction of pinion height adjusting washer. (Assemble as shown in the figure.)
^ Do not reuse pinion rear bearing inner race.
4. Assemble collapsible spacer to drive pinion.
CAUTION: Do not 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: Do not reuse pinion front bearing inner race.
7. Using suitable spacer, press the pinion front bearing inner race to drive pinion as far as drive pinion nut can be tightened.
8. Using the drift, install front oil seal as shown in the figure.
Tool number: ST30720000 (J-25405)
CAUTION:
^ Do not reuse oil seal.
^ When installing, do not incline oil seal.
^ Apply multi-purpose grease onto oil seal lips, and gear oil onto the circumference of oil seal.
9. Install companion flange.
NOTE: When reusing drive pinion, align the matching mark of drive pinion with the matching mark A of companion flange, 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: Do not reuse drive pinion lock nut.
11. Adjust to the drive pinion lock nut tightening torque and pinion bearing preload torque.
Tool number
A: KV40104000 ( - )
B: ST3127S000 (J-25765-A)
Drive pinion lock nut tightening torque: 147 - 323 Nm (15 - 32 kg-m, 109 - 238 ft. lbs.)
Drive pinion bearing preload: 2.65 - 3.23 Nm (0.27 - 0.32 kg-m, 24 - 28 inch lbs.)
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. Do not 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: Do not install rear cover yet.
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.
Differential Assembly
1. Install side gear thrust washer with the same thickness as the ones installed prior to disassembly or reinstall the old ones on the side gear.
2. Install side gear and thrust washer into differential case B.
CAUTION: Make sure that the circular clip is installed to side gear.
3. Install pinion mate assembly (pinion mate shaft, pinion mate gears and pinion mate thrust washers) into differential case B.
CAUTION: The pinion mate shaft groove side shall be installed to side gear.
4. Install viscous coupling into differential case B.
5. Install side gear thrust washer with the same thickness as the ones installed prior to disassembly or reinstall the old ones on the viscous coupling.
6. Align the matching marks and install differential case A into differential case B.
7. Measure side gear end play. If necessary, select the appropriate side gear thrust washer.
8. Align the matching mark of differential case with the mark of drive gear, then place drive gear.
9. Apply thread locking sealant into the thread hole of drive gear.
^ Use Genuine High Strength Thread Locking Sealant or equivalent.
CAUTION: Drive gear back and threaded holes shall be cleaned and degreased sufficiently.
10. Install drive gear on the mounting bolts, and then tighten to the specified torque. Refer to RFD-39, "COMPONENTS".
CAUTION:
^ Tighten bolts in a crisscross fashion.
^ After tightening the bolts to the specified torque, tighten the bolts additionally by turning the bolts 31 to 36 degrees.
11. Press side bearing inner races to differential case, using the drift and the base.
Tool number
A: KV38100300 (J-25523)
B: ST33061000 (J-8107-2)
CAUTION: Do not reuse side bearing inner race.
12. Install differential case assembly with side bearing outer races into gear carrier.
13. Measure side bearing preload. If necessary, select the appropriate side bearing adjusting washers.
14. Insert selected left and right side bearing adjusting washers in place between side bearings and gear carrier.
15. Align matching marks on bearing cap with that on gear carrier.
16. Install bearing caps and tighten bearing cap mounting bolts to the specified torque. Refer to RFD-39, "COMPONENTS".
17. Using the drift, drive side oil seals until it becomes flush with the case end.
Tool number: KV38100200 (J-26233)
CAUTION:
^ Do not reuse oil seal.
^ When installing, do not incline oil seal.
^ Apply multi-purpose grease onto oil seal lips, and gear oil onto the circumference of oil seal.
18. Check and adjust drive gear runout, tooth contact, drive gear to drive pinion backlash, and total preload torque.
Recheck above items. Readjust the above description, if necessary.
19. Apply sealant to mating surface of rear cover.
^ Use Genuine Silicone RTV or equivalent.
CAUTION: Remove old sealant adhering to mounting surfaces. Also remove any moisture, oil, or foreign material adhering to application and mounting surfaces.
20. Install rear cover on gear carrier and tighten mounting bolts with the specified torque. Refer to RFD-39, "COMPONENTS".
21. Install side flange with the following procedure.
NOTE: Install the RH side flange, then install the LH side flange. If LH side flange is installed first, the RH side flange comes out sometimes from the shock of installing the RH side flange.
a. Attach the protector to side oil seal.
Tool number: KV38107900 (J-39352)
b. After the side flange is inserted and the serrated part of side gear has engaged the serrated part of flange, remove the protector.
c. Put a suitable drift on the center of side flange, then drive it until sound changes.
NOTE: When installation is completed, driving sound of the side flange turns into a sound which seems to affect the whole final drive.
d. Confirm that the dimension of the side flange installation (Measurement A) in the figure comes into the following.
Measurement A: 326 - 328 mm (12.83 - 12.91 inch)