Beginning With VIN #343314

DIFFERENTIAL CARRIER





1. Press-fit front and rear bearing outer races with Tools. Tool numbers:
A ST30611000 (J25742-1)
B ST30621000 (J25742-5)
C ST30613000 (J25742-3)
2. Select pinion height adjusting washer. Refer to Adjustment. Adjustment





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





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.
Tool numbers:
A ST30720000(J25405)
B KV381 02510 ( - )





6. Install drive pinion washer, collapsible spacer and drive pinion in gear carrier.





7. Install companion flange and hold it firmly.
Insert pinion into companion flange by tapping its head with a soft hammer.





8. Temporarily tighten pinion nut until there is no axial play.
The threaded portion of drive pinion and pinion nut should be free from oil or grease.
Tool number: KV38108300 (J44195)





9. Tighten pinion nut by degrees to the specified preload while checking the preload with Tools.
When checking preload, turn drive pinion in both directions several times to seat bearing rollers correctly.
Pinion bearing preload: 1.1 - 1.6 Nm (11 - 16 kg-cm, 9.5 - 13.9 inch lbs.)
Tool number: ST3127SO00 (J25765-A)

CAUTION: The preload is achieved by the permanent setting of the collapsible spacer. So, if an over pre-load results from turning of the pinion nut excessively, the spacer should be replaced by new one.





10. Install differential case assembly with side bearing outer races into gear carrier.





11. Align mark on bearing cap with that on gear carrier and install bearing cap on gear carrier.





12. Measure ring gear-to-drive pinion backlash with a dial indicator
Ring gear-to-drive pinion backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)
- If backlash is too small, decrease thickness of left shim and increase thickness of right 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.





13. Check total preload with Tool.
When checking preload, turn drive pinion in both directions several times to set bearing rollers.
Tool number: ST3127S000 (J25765-A)
Total preload: 1.2 - 2.2 Nm (12 - 22 kg-cm, 10 - 19 inch lbs.)





- If preload is too great, remove the same amount of shims from each side.
- If preload is too small, add the same amount of shims 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.
14. Recheck ring gear-to-drive pinion backlash because an increase or decrease in thickness of shims will cause change of ring gear-to-pinion backlash.





15. 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.
16. Check tooth contact. Refer to Adjustment. Adjustment