Reassembly
REASSEMBLY
Lubrication And Adhesion Points
Reassembly Service Points
>A< Oil Seal Press Fitting
1. With the special tool, press fit the oil seal until it is flush with the end of the gear carrier.
2. Apply multipurpose grease to the oil seal lip.
>B< Drive Pinion Rear Bearing Outer Race/Drive Pinion Front Bearing Outer Race Installation
CAUTION: Be careful not to press in the outer race at an angle.
>C< Pinion Height Adjustment
Adjust the drive pinion height by the following procedures:
1. Apply a thin coat of the multipurpose grease to the mating face of the washer of the special tool.
2. Install special tools and drive pinion front and rear bearing inner races on the gear carrier in the sequence shown in the illustration.
NOTE: Apply a thin coat of the multipurpose grease to the mating face of the washer of the special tool.
3. Gradually tighten the nut of the special tool while checking the drive pinion turning torque until the standard value of drive pinion turning torque is obtained.
Standard Value:
NOTE: Because the special tool cannot be turned one turn, turn it several times within the range that it can be turned; then, after fitting to the bearing, measure the rotation torque.
4. Clean the side bearing seat thoroughly.
5. Position the special tool in the side bearing seat of the gear carrier, and then install the bearing cap.
NOTE: When positioning the special tool, be sure that the cutout sections of the special tool are in the position shown in the illustration. And check that the special tool is in close contact with the side bearing seat.
6. Use a feeler gauge to measure the clearance (A) between the special tools.
7. Remove the special tools (MB990392 and MB990836).
8. Use a micrometer to measure the dimensions (B) and (C) of the special tools.
9. Install the bearing cap, and then use a cylinder gage and the micrometer to measure the inside diameter D of the bearing cap as shown in the illustration.
10. Calculate the thickness (E) of the drive pinion rear shim from the following equation, and select the shim that is closest in thickness to this value.
E = A + B + C-1/2 D-86.00 mm (3.39 inch)
11. Fit the selected drive pinion rear shim(s) to the drive pinion, and press-fit the drive pinion rear bearing inner race by using the special tool.
>D< Drive Pinion Preload Adjustment
Adjust the drive pinion turning torque by using the following procedures:
1. Fit the drive pinion front shim(s) between the drive pinion spacer and the drive pinion front bearing inner race.
2. Tighten the companion flange to the specified torque by using the special tools.
NOTE: Do not install the oil seal.
3. Measure the drive pinion turning torque (without the oil seal) by using the special tools.
Standard Value:
4. If the drive pinion turning torque is not within the range of the standard value, adjust the turning torque by replacing the drive pinion front shim(s) or the drive pinion spacer.
NOTE: When selecting the drive pinion front shims, if the number of shims is large, reduce the number of shims to a minimum by selecting the drive pinion spacers.
5. Remove the companion flange and drive pinion once again. Drive the oil seal into the gear carrier front lip by using the special tool. Apply multipurpose grease to the oil seal lip.
6. Apply a thin coat of multipurpose grease to the companion flange contacting surface of the washer and oil seal contacting surface before installing drive pinion assembly.
7. Install the drive pinion assembly and companion flange with mating marks properly aligned, and tighten the companion flange self-locking nut to the specified torque by using the special tools.
8. Measure the drive pinion turning torque (with oil seal) by using the special tools to verify that the drive pinion turning torque complies with the standard value.
Standard Value:
If there is a deviation from the standard value, check whether or not there is incorrect tightening torque of the companion flange tightening self-lock nut, or incorrect fitting of the oil seal.
>E< Differential Gear Backlash Adjustment
Adjust the differential gear backlash by the following procedures:
1. Assemble the side gears, side gear spacers, pinion gears, and pinion washers into the differential case.
2. Temporarily install the pinion shaft.
NOTE: Do not drive in the lock pin yet.
3. While locking the side gear with the wedge, measure the differential gear backlash with a dial indicator on the pinion gear.
NOTE:
1. The measurement should be made for both pinion gears individually.
2. Measure the limited slip differential gear backlash.
Standard value: 0 - 0.076 mm (0 - 0.0030 inch)
Limit: 0.2 mm (0.008 inch)
4. If the differential gear backlash exceeds the limit, adjust the backlash by installing thicker side gear spacers.
5. Measure the differential gear backlash once again, and confirm that it is within the limit.
NOTE:
1. After adjustment, check that the backlash is less than the limit and differential gear rotates smoothly.
2. When adjustment is impossible, replace the side gear and the pinion gear as a set.
>F< Lock Pin Installation
1. Align the pinion shaft lock pin hole with the differential case lock pin hole, and drive in the lock pin.
2. Stake the lock pin with a punch on both sides.
>G< Drive Gear Installation
1. Clean the drive gear attaching bolts.
2. Remove the adhesive adhering to the threaded holes of the drive gear by turning M10 x 1.25 tap, and then clean the threaded holes by applying compressed air.
3. Apply the specified adhesive to the threaded holes of the drive gear.
Specified adhesive: 3M Stud Locking Part No. 4170 or equivalent
4. Install the drive gear onto the differential case with the mating marks properly aligned. Tighten the bolts to the specified torque [80 - 90 Nm (58 - 65 ft. lbs.)] in a diagonal sequence.
>H< Side Bearing Inner Race Press-Fitting
>I< Drive Gear Backlash Adjustment
Adjust the drive gear backlash by the following procedures:
1. Install the side bearing spacers, which are thinner than those removed, to the side bearing outer races, and then mount the differential case assembly into the gear carrier.
NOTE: Select side bearing spacers with the same thickness for both the drive pinion side and the drive gear side.
2. Push the differential case to one side, and measure the clearance between the gear carrier and the side bearing.
3. Measure the thickness of the side bearing spacers on one side, select two pairs of spacers which correspond to that thickness plus one half of the clearance plus 0.05 mm, and then install one pair each to the drive pinion side and the drive gear side.
4. Install the side bearing spacers and differential case assembly, as shown in the illustration, to the gear carrier.
5. Tap the side bearing spacers with a brass bar to fit them to the side bearing outer race.
6. Align the mating marks on the gear carrier and the bearing cap, and then tighten the bearing cap.
7. With the drive pinion locked in place, measure the drive gear backlash with a dial indicator on the drive gear.
NOTE: Measure at four points or more on the circumference of the drive gear.
Standard value: 0.11 - 0.16 mm (0.004 - 0.006 inch)
8. Change the side bearing spacers as illustrated, and then adjust the drive gear backlash between the drive gear and the drive pinion.
NOTE: When increasing the number of side bearing spacers, use the same number for each, and as few as possible.
9. Check the drive gear and drive pinion for tooth contact. If poor contact is evident, make adjustment.
10. Measure the drive gear runout at the shoulder on the reverse side of the drive gear.
Limit: 0.05 mm (0.002 inch)
11. If the drive gear runout exceeds the limit, reinstall by changing the phase of the drive gear and differential case, and remeasure.