Part 2

FRONT FINAL DRIVE ASSEMBLY Continued


Disassembly and Assembly


COMPONENTS (VQ35HR)









COMPONENTS (VK45DE)










9. If the turning torque is outside the specification, use a thicker/thinner side bearing adjusting shim to adjust. Refer to Inspection and Adjustment.






If the turning torque is less than the specified range: Decrease the side bearing adjusting shim thickness.
If the turning torque is greater than the specification: Increase the side bearing adjusting shim thickness.

10. Record the total amount of shim thickness required for the correct carrier side bearing preload.

Pinion Gear Height
If the hypoid gear set has been replaced, select the pinion height adjusting washer.





1. Use the formula below to calculate pinion height adjusting washer thickness.

Washer selection equation:
T = T0 + (t1 - t2)
T: Correct washer thickness
T0: Removed washer thickness
t1: Old drive pinion head letter "H � 0.01" ("H": machined tolerance 1/100 mm � 100)
t2: New drive pinion head letter "H � 0.01" ("H": machined tolerance 1/100 mm � 100)


Example:
T = 3.21 + [(2 � 0.01) - (-1 � 0.01)] = 3.24
T0: 3.21
t1: +2
t2: -1

2. Select the proper pinion height adjusting washer. Refer to Inspection and Adjustment.
If impossible find the desired thickness of washer, use washer with thickness closest to the calculated value.

Example:
Calculated value... T = 3.22 mm
Used washer... T = 3.21 mm


Pinion Bearing Preload
- Assemble the drive pinion parts if they are disassembled. Refer to "Drive Pinion Assembly".
1. Make sure all parts are clean. Also, make sure the bearings are well lubricated with gear oil.





2. 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 (1).
3. Temporarily tighten removed drive pinion lock nut to drive pinion.

NOTE:
Use removed drive pinion lock nut only for the preload measurement.
4. Rotate drive pinion at least 20 times to check for smooth operation of the bearing.
5. Tighten to drive pinion lock nut, while adjust pinion bearing preload torque.

Tool number A: ST3127S000 (J-25765-A)

Drive pinion lock nut tightening torque: 127.4 - 245.0 N�m (13.0 - 25.0 kg-m, 94 - 181 ft-lb)

Pinion bearing preload: 0.78 - 1.57 N�m (0.08 - 0.16 kg-m, 7 - 13 in-lb)







CAUTION:
- Adjust to the lower limit of the drive pinion lock nut tightening torque first.
- After adjustment, rotate drive pinion back and forth 2 to 3 times to check for unusual noise, rotation malfunction,
and other malfunctions.
6. If the pinion bearing preload torque is outside the specification, use a thicker/thinner drive pinion bearing adjusting washer and drive pinion adjusting washer to adjust. Refer to Inspection and Adjustment.

When the preload torque is large:
Decrease the drive pinion bearing adjusting washer and drive pinion adjusting washer thickness.
When the preload is small:
Increase the drive pinion bearing adjusting washer and drive pinion adjusting washer thickness.

7. Remove companion flange, after adjustment.

ASSEMBLY

Drive Pinion Assembly
1. Install pinion front and rear bearing outer races using drifts.






Tool number A: ST37820000 ( - )


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. Temporarily install pinion height adjusting washer (1).

When hypoid gear set has been replaced
- Select pinion height adjusting washer. Refer to "Pinion Gear
Height".

When hypoid gear set has been reused
- Temporarily install the removed pinion height adjusting washer or same thickness washer to drive pinion.





3. Install selected pinion height adjusting washer (2) to drive pinion. Press pinion rear bearing inner race (1) to it, using drift.

Tool number A: ST30032000 (J-26010-01)


CAUTION:
- Pay attention to the direction of pinion height adjusting washer. (Assemble as shown in the figure.)
- Never reuse pinion rear bearing inner race.





4. Temporarily assemble removed drive pinion adjusting washer and drive pinion bearing adjusting washer or same thickness them to drive pinion.
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. Adjust pinion bearing preload. If necessary, select the appropriate drive pinion adjusting washer and drive pinion bearing adjusting washer. Refer to "Pinion Bearing Preload".





9. Using the drifts, install front oil seal as shown in figure.

Tool number
A: ST33400001 (J-26082)
B: KV38102510 ( - )


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.





10. 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 (1).
11. Apply anti-corrosion oil to the thread and seat of new drive pinion lock nut, and temporarily tighten drive pinion lock nut to drive pinion.

CAUTION:
Never reuse drive pinion lock nut.
12. Tighten to drive pinion lock nut, while adjust pinion bearing preload torque.

Tool number A: ST3127S000 (J-25765-A)

Drive pinion lock nut tightening torque: 127.4 - 245.0 N�m (13.0 - 25.0 kg-m, 94 - 181 ft-lb)

Pinion bearing preload: 0.78 - 1.57 N�m (0.08 - 0.16 kg-m, 7 - 13 in-lb)







CAUTION:
- Adjust to the lower limit of the drive pinion lock nut tightening torque first.
- After adjustment, rotate drive pinion back and forth 2 to 3 times to check for unusual noise, rotation malfunction, and other malfunctions.
13. Install differential case assembly. Refer to "Differential Assembly".

CAUTION:
Never install carrier cover yet.
14. Check and adjust drive gear runout, tooth contact, drive gear to drive pinion backlash, and companion flange runout. Refer to "Drive Gear Runout", "Tooth Contact", "Backlash", "Companion Flange Runout".
Recheck above items. Readjust the above description, if necessary.
15. Check total preload torque. Refer to "Total Preload Torque".
16. Install carrier cover. Refer to "Differential Assembly".

Differential Assembly
1. Install side gear thrust washers with the same thickness as the ones installed prior to disassembly or reinstall the old ones on the side gears.





2. Install side gears and thrust washers into differential case.

CAUTION:
- Never reuse circular clip.





- Make sure that the circular clip is installed to side gear
(side retainer side).
3. Align 2 pinion mate gears in diagonally opposite positions, then rotate and install them into differential case after installing thrust washer to pinion mate gear.





4. Align the lock pin holes on differential case with shaft, and install pinion mate shaft.
5. Measure side gear end play. If necessary, select the appropriate side gear thrust washers. Refer to "Differential Side Gear Clearance".





6. Drive a lock pin into pinion mate shaft, using a punch.
Make sure lock pin is flush with differential case.

CAUTION:
Never reuse lock pin.





7. Align the matching mark of drive gear with the mark of differential case, then place drive gear.
8. Apply thread locking sealant into the thread hole of drive gear.





- Use Genuine Medium Strength Thread Locking Sealant or equivalent. Refer to Recommended Chemical Products and Sealants.

CAUTION:
Drive gear back and threaded holes shall be cleaned and degreased sufficiently.





9. Install drive gear on the mounting bolts, and then tighten to the specified torque. Refer to Front Final Drive Assembly.

CAUTION:
Tighten bolts in a crisscross fashion.





10. Press side bearing inner races to differential case, using the drift and the base.

Tool number
A: ST33230000 (J-25805-01)
B: ST33061000 (J-8107-2)


CAUTION:
Never reuse side bearing inner race.





11. Press-fit side bearing outer race into side retainer with the drift and the drift bar.

Tool number
A: ST30611000 (J-25742-1)
B: KV31103000 (J-38982)


CAUTION:
- At first, using a hammer, tap bearing outer race until it becomes flat to side retainer.
- Never reuse side bearing outer race.





12. Press-fit side bearing outer race into gear carrier with the drift and the drift bar.

Tool number
A: ST30611000 (J-25742-1)
B: KV31103000 (J-38982)


CAUTION:
- At first, using a hammer, tap bearing outer race until it becomes flat to gear carrier.
- Never reuse side bearing outer race.





13. Place the differential case assembly into gear carrier.
14. Measure side bearing preload. If necessary, select the appropriate side bearing adjusting shim. Refer to "Side Bearing Preload".





15. Install selected side bearing adjusting shim (1).
16. Apply multi-purpose grease to O-ring (2), and install it to side retainer.

CAUTION:
Never reuse O-ring.
17. Install side retainer assembly to gear carrier.





18. Install side retainer mounting bolts to the specified torque. Refer to Front Final Drive Assembly.
19. Using the drift, press-fit side oil seal so that its surface comes face to face with the end surface of the side retainer.






Tool number A: ST33400001 (J-26082)


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.





20. Using the drift, press-fit side oil seal so that its surface comes face to face with the end surface of gear carrier.

Tool number A: KV38102100 (J-25803-01)


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.
21. Apply multi-purpose grease to O-ring, and install it to gear carrier.

CAUTION:
Never reuse O-ring.
22. Check and adjust drive gear runout, tooth contact, drive gear to drive pinion backlash, and total preload torque. Refer to "Drive Gear Runout", "Tooth Contact", "Backlash", "Total Preload Torque".
Recheck above items. Readjust the above description, if necessary.





23. Apply sealant to mating surface of carrier cover.
- Use Genuine Silicone RTV or equivalent. Refer to Recommended Chemical Products and Sealants.

CAUTION:
Remove old sealant adhering to mounting surfaces. Also remove any moisture, oil, or foreign material adhering to application and mounting surfaces.





24. Install carrier cover on gear carrier and tighten mounting bolts with the specified torque. Refer to Front Final Drive Assembly.

Side Shaft Assembly
1. Using the drift, install side shaft oil seal.






Tool number A: KV38100200 ( - )


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.
2. Install dust sealed.





3. Support side shaft bearing with the drift, then press side shaft (1) into the side shaft bearing using a press.

Tool number A: ST30032000 (J-26010-01)

4. Apply multi-purpose grease to O-ring, and install it to extension tube retainer.

CAUTION:
Never reuse O-ring.