Adjustment

DIFFERENTIAL ASSEMBLY


Adjustment


TOTAL PRELOAD TORQUE
Before inspection and adjustment, drain gear oil.
1. Secure final drive assembly onto an attachment [SST: KV38100800 (J-25604-01)].
2. Rotate drive pinion back and forth 2 to 3 times to check for unusual noise and rotation malfunction.





3. Rotate drive pinion at least 20 times to check for smooth operation of the bearing.
4. Measure total preload with the preload gauge (A) [SST:
ST3127S000 (J-25765-A)].

Standard
Total preload torque : Refer to Preload Torque.


NOTE:
Total preload torque = Pinion bearing preload torque + Side bearing preload torque
- If measured value is out of the specification, disassemble it to check and adjust each part. Adjust the pinion bearing preload and side bearing preload.
Adjust the pinion bearing preload first, then adjust the side bearing preload.

When the preload torque is large
On pinion bearings: Replace the collapsible spacer.
On side bearings: Use thinner side bearing adjusting washers by the same amount to each side. For selecting adjusting washer, refer to the latest parts information.


When the preload is small
On pinion bearings: Tighten the drive pinion lock nut.
On side bearings: Use thicker side bearing adjusting washers by the same amount to each side. For selecting adjusting washer, refer to the latest parts information.


DRIVE GEAR RUNOUT
1. Remove rear cover. Disassembly.
2. Following the procedure below, install a dummy cover set [SST: KV381091S0 ( -- )] to gear carrier.
a. Temporarily tighten dummy cover to gear carrier.
b. Position colors and dummy cover spacers to dummy cover.
c. Tighten rear cover mounting bolts to the specified torque with colors. Exploded View.
d. Tighten dummy cover spacer mounting bolts evenly to the specified torque.

Tightening torque : 5.9 Nm (0.6 kg-m)






3. Fit a dial indicator to the drive gear back face.
4. Rotate the drive gear to measure runout.

Drive gear back face runout : Refer to Drive Gear Runout.

- If the runout is outside of the repair limit, check drive gear assembly condition; foreign material may be caught between drive gear and differential case, or differential case or drive gear may be deformed, etc.

CAUTION:
Replace drive gear and drive pinion as a set.

TOOTH CONTACT
1. Remove rear cover. Disassembly.
2. Following the procedure below, install a dummy cover set [SST: KV381091S0 ( -- )] to gear carrier.
a. Temporarily tighten dummy cover to gear carrier.
b. Position colors and dummy cover spacers to dummy cover.
c. Tighten rear cover mounting bolts to the specified torque with colors. Exploded View.
d. Tighten dummy cover spacer mounting bolts evenly to the specified torque.

Tightening torque : 5.9 Nm (0.6 kg-m)






3. Apply red lead to drive gear.

CAUTION:
Apply red lead to both the faces of 3 to 4 gears at 4 locations evenly spaced on drive gear.





4. Rotate drive gear back and forth several times, check drive pinion gear to drive gear tooth contact.

CAUTION:
Check tooth contact on drive side and reverse side.
Tooth Contact Judgment Guide










5. If tooth contact is improperly adjusted, follow the procedure below to adjust the pinion height (dimension X).





- If the tooth contact is near the face (face contact), or near the heel (heel contact), thicken drive pinion height adjusting washer to move drive pinion closer to drive gear.
For selecting adjusting washer, refer to the latest parts information.





- If the tooth contact is near the flank (flank contact), or near the toe (toe contact), thin drive pinion height adjusting washer to move drive pinion farther from drive gear.
For selecting adjusting washer, refer to the latest parts information.

BACKLASH
1. Remove rear cover. Disassembly.
2. Following the procedure below, install a dummy cover set [SST: KV381091S0 ( -- )] to gear carrier.
a. Temporarily tighten dummy cover to gear carrier.
b. Position colors and dummy cover spacers to dummy cover.
c. Tighten rear cover mounting bolts to the specified torque with colors. Exploded View.
d. Tighten dummy cover spacer mounting bolts evenly to the specified torque.

Tightening torque : 5.9 Nm (0.6 kg-m)





3. Fit a dial indicator to the drive gear face to measure the backlash.

Backlash : Refer to Backlash.

- If the backlash is outside of the specified value, change the thickness of side bearing adjusting washers.

When the backlash is large:
Make drive gear back side adjusting washer thicker, and drive gear tooth side adjusting washer thinner by the same amount. For selecting adjusting washer, refer to the latest parts information.
When the backlash is small:
Make drive gear back side adjusting washer thinner, and drive gear tooth side adjusting washer thicker by the same amount. For selecting adjusting washer, refer to the latest parts information.

CAUTION:
Never change the total amount of washers as it changes the bearing preload.