Assembly

DRIVE PINION


Assembly






1. Install front bearing outer race (1) and rear bearing outer race
(2) using drifts.

A : Drift [SST: ST30720000 (J-25405)]
B : Drift [SST: KV40105230 ( - )]
C : Drift bar [SST: ST30611000 (J-25742-1)]
D : Drift [SST: ST30621000 (J-25742-5)]


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. Adjustment.

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

CAUTION:
Pay attention to the direction of pinion height adjusting washer. (Assemble as shown in the figure.)





3. Install pinion rear bearing inner race (1) to drive pinion with the drift (A) [SST: ST30901000 (J-26010-01)].

CAUTION:
Never reuse pinion rear bearing inner race.
4. Check and adjust the tooth contact and back lash of drive gear and drive pinion following the procedure below.
a. Assemble drive pinion into gear carrier.

CAUTION:
- Never assemble a collapsible spacer.
- Apply gear oil to pinion rear bearing.
b. Assemble pinion front bearing inner race to drive pinion assembly.

CAUTION:
- Never reuse pinion front bearing inner race.
- Apply gear oil to pinion front bearing.





c. Using suitable spacer (A) (commercial service tool), press the pinion front bearing inner race to drive pinion as far as drive pinion nut can be tightened.





d. Install companion flange (1).

CAUTION:
Never assemble front oil seal.

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).





e. Temporarily tighten removed drive pinion nut to drive pinion using flange wrench (commercial service tool).

NOTE:
Use removed drive pinion nut only for the preload measurement.
f. Rotate drive pinion more than 20 times to adjust bearing.
g. Tighten to drive pinion lock nut using flange wrench (commercial service tool), while adjusting pinion bearing preload torque using preload gauge (A) [SST: ST3127S000 (J-25765-A)].

Pinion bearing preload (without oil seal) : 1.0 - 1.3 Nm (0.11 - 0.13 kg-m, 9 - 11 in-lb)

CAUTION:
Drive pinion lock nut is tightened with no collapsible spacer. Be careful not to overtighten it. While measuring the preload, tighten it by 5� to 10�.
h. Assemble removed drive side bearing adjusting washer or same thickness of it and install differential case assembly. Assembly.

CAUTION:
Apply differential gear oil to the side bearings.
i. Check and adjust tooth contact, drive gear to drive pinion backlash. Adjustment.
j. Remove differential case assembly.
k. Remove companion flange.
l. Remove drive pinion assembly from gear carrier.
m. Remove pinion front bearing inner race.
5. Assemble collapsible spacer.

CAUTION:
Never reuse collapsible spacer.
6. Assemble drive pinion into gear carrier.

CAUTION:
Apply gear oil to pinion rear bearing.
7. Assemble pinion front bearing inner race to drive pinion assembly.

CAUTION:
- Never reuse pinion front bearing inner race.
- Apply gear oil to pinion front bearing.





8. Using suitable spacer (A) (commercial service tool), press the pinion front bearing inner race to drive pinion as far as drive pinion nut can be tightened.





9. Install front oil seal as shown in figure with the drift (A) [SST:
KV40104710 ( -- )].

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 drive pinion lock nut, and temporarily tighten drive pinion lock nut to drive pinion, using flange wrench (commercial service tool).

CAUTION:
Never reuse drive pinion lock nut.
12. Adjust to the drive pinion lock nut tightening torque and pinion bearing preload torque, using preload gauge (A) [SST:
ST3127S000 (J-25765-A)].

Pinion bearing preload : Refer to Preload Torque

load Torque"

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. Never 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.
13. Install differential case assembly. Assembly.

CAUTION:
Never install rear cover at this timing.
14. Check and adjust drive gear runout, tooth contact, and drive gear to drive pinion backlash. Adjustment.
15. Check total preload torque. Adjustment.
16. Install rear cover. Assembly.