Part 2

PINION HEIGHT ADJUSTING WASHER SELECTION





11. Now, position the side bearing discs, J25269-4, and arbor firmly into the side bearing bores.





12. Install the side bearing caps and tighten the cap bolts.

Specification: 88 - 98 Nm (9 - 10 kg.m, 65 - 72 ft. lbs.)





13. Select the correct standard pinion height adjusting washer thickness by using a standard gauge of 3.0 mm (0.118 inch) and your J34309-101 feeler gauge. Measure the gap between the J34309-11 "R200A" pinion height adapter and the arbor.





14. Write down your exact total measurement.





15. Correct the pinion height washer size by referring to the "pinion head number".









There are two numbers painted on the pinion gear. The first one refers to the pinion and ring gear as a matched set and should be the same as the number on the ring gear. The second number is the "pinion head height number", and it refers to the ideal pinion height from standard for quietest operation. Use the following chart to determine the correct pinion height washer. Refer to image.





16. Remove the J34309 pinion preload shim selector tool from the final drive housing and disassemble to retrieve the pinion bearings.

TOOTH CONTACT
Gear tooth contact pattern check is necessary to verify correct relationship between ring gear and drive pinion. Hypoid gear sets which are not positioned properly in relation to one another may be noisy, or have short life, or both. With a pattern check, the most desirable contact for low noise level and long life can be assured.





1. Thoroughly clean ring gear and drive pinion teeth.
2. Sparingly apply a mixture of powdered ferric oxide and oil or equivalent to 3 or 4 teeth of ring gear drive side.








3. Hold companion flange steady by hand and rotate the ring gear in both directions.

ASSEMBLY
DIFFERENTIAL SIDE SHAFT








1. Install oil seal and grease seal.





2. Install extension tube retainer, rear axle bearing and rear axle shaft bearing collar on differential side shaft.

DIFFERENTIAL CASE





1. Install side gears, pinion mate gears and thrust washers into differential case.





2. Fit pinion mate shaft to differential case so that it meets lock pin holes.





3. Adjust backlash between side gear and pinion mate gear by selecting side gear thrust washer. Refer to image.

Backlash between side gear and pinion mate gear (Clearance between side gear thrust washer and differential case): Less than 0.15 mm (0.0059 inch)





4. Install pinion mate shaft lock pin with a punch.
Make sure lock pin is flush with case.





5. Apply gear oil to gear tooth surfaces and thrust surfaces and check to see they turn properly.





6. Install differential case assembly on ring gear.
7. Apply locking agent [Locktite (stud lock) or equivalent] to ring gear bolts, and install them.
Tighten bolts in a criss-cross pattern, lightly tapping bolt head with a hammer.





8. Press-fit side bearing inner cones on differential case with Tool.
Tool number:
A KV38100300 (J25523)
B ST33061000 (J8107-2)

FINAL DRIVE HOUSING





1. Press-fit front and rear bearing outer races with Tools.

Tool number:
A ST30611000 (J25742-1)
B ST30621000 (J25742-5)
C ST30613000 (J25742-3)





2. Select drive pinion height adjusting washer and pinion bearing adjusting washer.
3. Install drive pinion height adjusting washer in drive pinion, and press-fit pinion rear bearing inner cone in it, using press and Tool.

Tool number: ST30901000 (J26010-01)





4. Place pinion front bearing inner cone in final drive housing.





5. Apply multi-purpose grease to cavity at sealing lips of oil seal. Install front oil seal.

Tool number: KV38100500 (J25273)





6. Place drive pinion bearing spacer, drive pinion bearing adjusting washer and drive pinion in final drive housing.





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





8. Tighten pinion nut to the specified torque.
The threaded portion of drive pinion and pinion nut should be free from oil or grease.

Tool number: ST38060002 (J34311)





9. Turn drive pinion in both directions several revolutions, and measure pinion bearing preload.

Tool number: ST3127SO00 (J25765-A)
Pinion bearing preload: 1.1 - 1.4 Nm (11 - 14 kg-cm, 9.5 - 12.2 inch lbs.)

When pinion bearing preload is outside the specifications, replace pinion bearing adjusting washer and spacer with a different thickness.





10. Select side bearing adjusting washer.
11. Install differential case assembly with side bearing outer races into final drive housing.





12. Insert left and right side bearing adjusting washers in place between side bearings and final drive housing.





13. Drive in side bearing spacer with Tool.

Tool number: KV38100600 (J25267)





14. Align mark on bearing cap with that on final drive housing and install bearing cap on final drive housing.





15. Apply Multi-Purpose grease to cavity at sealing lips of oil seal. Install side oil seal.

Tool number: KV38100200 (J26233)





16. Measure ring gear to drive pinion backlash with a dial indicator.

Ring gear-to-drive pinion backlash: 0.10 - 0.15 mm (0.0039 - 0.0059 inch)

- If backlash is too small, decrease thickness of right shim and increase thickness of left shim by the same amount. If backlash is too great, reverse the above procedure.

Never change the total amount of shims as it will change the bearing preload.





17. Check total preload with Tool.
When checking preload, turn drive pinion in both directions several times to set bearing rollers.

Tool number: ST3127SO00 (J25765-A)
Total preload: 1.4 - 1.7 Nm (14 - 17 kg.cm, 12 - 15 inch lbs.)





- If preload is too great, remove the same amount of shim from each side.
- If preload is too small, add the same amount of shim to each side.

Never add or remove a different number of shims for each side as it will change ring gear to drive pinion backlash.

18. Recheck ring gear to drive pinion backlash because increase or decrease in thickness of shims will cause change of ring gear-to-pinion backlash.





19. Check runout of ring gear with a dial indicator.

Runout limit: 0.05 mm (0.0020 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.

20. Check tooth contact.
21. Install rear cover and gasket.





22. Install differential side shaft assembly.