Differential Carrier

1. Press-fit front and rear bearing outer races with Tool numbers:
(A): ST30611000 (J25742-1)
(B): ST30621000 (J25742-5)
(C): ST30613000 (J25742-3)





2. Select drive pinion adjusting. Adjustment
3. Install drive pinion adjusting washer in drive pinion, and press fit pinion rear bearing inner cone in it, with press and Tool number ST30901000 (J26010-01) washer.





4. Place pinion front bearing inner cone in gear carrier.





5. Apply multi-purpose grease to cavity at sealing lips of oil seal. Install front oil seal with Tool numbers:
(A): ST30720000 (J25405)
(B): KV38102510





6. Install drive pinion bearing spacer, pinion bearing adjusting shim and drive pinion in gear carrier.





7. Insert companion flange into drive pinion by tapping the companion flange with a soft hammer.





8. Tighten pinion nut to the specified torque. Use Tool number KV38104700 (J34311). The threaded portion of drive pinion and pinion nut should be free from oil or grease.





9. Turn drive pinion in both directions several times, and measure pinion bearing preload with Tool number ST3127SOOO (J25765-A).
Pinion bearing preload (Without front oil seal): 1.2 - 1.5 Nm (10 - 13 inch lbs.)
- If preload is out of specification, adjust the thickness of spacer and shim combination by replacing shim and spacer with thinner one.
- Start from the combination of thickest spacer and shim.
- Combine each spacer and shim thickness one by one until the correct specification is achieved.
10. Install differential case assembly with side bearing outer races into gear carrier.





11. Position side bearing adjusters on gear carrier with threads properly engaged; screw in adjusters lightly at this stage of assembly with Tool number ST32580000 (J34312).





12. Align mark on bearing cap with that on gear carrier and install bearing cap on gear carrier.
- Do not tighten at this point to allow further tightening of side bearing adjusters.





13. Tighten both right and left side bearing adjusters alternately and measure ring gear backlash and total preload at the same time. Adjust right and left side bearing adjusters by tightening them alternately so that proper ring gear backlash and total preload can be obtained.
Ring gear-to-drive pinion backlash: 0.15 - 0.20 mm (0.0059 - 0.0079 inch)





- When checking preload, turn drive pinion in both directions several times to set bearing rollers. Use Tool number ST3127S000 (J25765-A).
Total preload: 1.7 - 2.5 Nm (15 - 22 inch lbs.)





14. Tighten side bearing cap bolts.
15. Install side lock finger in place to prevent rotation during operation.





16. Check runout of ring gear with a dial indicator.
Runout limit: 0.08 mm (0.0031 inch)
- If backlash varies excessively in different places, the variance may have resulted from foreign matter caught between the ring gear and the differential case.
- If the backlash varies greatly when the runout of the ring gear is within a specified range, the hypoid gear set or differential case should be replaced.
17. Check tooth contact.