Assembly
ASSEMBLY
NOTE:
^ Assemble in the reverse order of disassembling.
^ Check and adjust each part during assembly.
^ Keep the shims and washers in order, so that they are not improperly installed.
^ Thoroughly clean the surfaces on which the shims, washers and bearings are to be installed.
^ Apply gear oil when installing the bearings and thrust washers.
^ Be careful not to mix up the right and left hand races of the bearings.
^ Use a new O-ring and gasket.
^ Replace the oil seal with a new one at every disassembly. Apply chassis grease between the lips when installing the oil seal.
^ Be careful not to confuse the installing direction of oil seal.
1. Adjusting preload for front and rear bearings
Adjust the bearing preload with spacer and washer between front and rear bearings. Pinion height adjusting washer are not affected by this adjustment. The adjustment must be carried out without oil seal inserted.
1. Press the rear bearing race into differential carrier using ST1 and ST2.
ST1 398477701 HANDLE
ST2 398477703 DRIFT2
2. Install the front bearing race to differential carrier using ST1 and ST2.
ST1 398477701 HANDLE
ST2 398477703 DRIFT 2
3. Insert the ST1 into carrier with pinion height adjusting washer and rear bearing cone fitted onto it.
NOTE:
^ If tooth contact (Drive pinion, Crown gear) is normal in the inspection before disassembling, verify that the washer is not deformed, and then re-use the used washer.
^ Use a new rear bearing cone.
4. Then install the preload adjusting spacer and washer, front bearing cone, ST2, companion flange, and washer and drive pinion nut.
ST1 398507702 DUMMY SHAFT
ST2 398507703 DUMMY COLLAR
5. Turn the ST1 with hand to make it seated, and tighten the drive pinion nut while measuring the preload with spring balance. Select the preload adjusting washer and spacer so that the specified preload is obtained when nut is tightened to the specified torque.
NOTE:
^ Use a new lock nut.
^ Be careful not to give excessive preload.
^ When tightening the drive pinion nut, lock ST-I with ST2 as shown in the figure.
^ Measure the preload in direction of tangent to flange.
ST1 398507702 DUMMY SHAFT
ST2 398507704 BLOCK
2. Adjusting drive pinion height
Adjust the drive pinion height with shim installed between the rear bearing cone and back of pinion gear.
1. Install the ST2.
NOTE: At this time, install a pinion height adjusting shim which is temporarily selected or the same as that used before. Measure and record the thickness.
ST1 398507702 DUMMY SHAFT
ST2 398507701 DIFFERENTIAL CARRIER GAUGE
ST3 398507703 DUMMY COLLAR
2. Measure the clearance N between the end of ST2 and end surface of ST1 by using a thickness gauge.
NOTE: Make sure there is no clearance between the case and ST2.
ST1 398507702 DUMMY SHAFT
ST2 398507701 DIFFERENTIAL CARRIER GAUGE
3. Obtain the thickness of pinion height adjusting shim to be inserted from the following formula, and replace the temporarily installed shim with this one.
T = To + N - (H x 0.01) - 0.20 mm (0.0079 inch)
NOTE: Use copies of this page.
(Example of calculation)
To = 2.20 + 1.20 = 3.40 mm
N = 0.23 mm H = + 1
T = 3.40 + 0.23 - 0.01 - 0.20 = 3.42
Result: Thickness = 3.42 mm
Therefore use the shim 383605200.
3. Install the selected pinion height adjusting shim on drive pinion, and press the rear bearing cone into position with ST.
ST 398177700 INSTALLER
4. Insert the drive pinion into differential carrier, install the previously selected bearing preload adjusting spacer and washer.
5. Press-fit the front bearing cone into case with ST1, ST2 and ST3.
ST1 398507703 DUMMY COLLAR
ST2 399780104 WEIGHT
ST3 899580100 INSTALLER
6. Insert the spacer, then press-fit the pilot bearing with ST1 and ST2.
ST1 399780104 WEIGHT
ST2 899580100 INSTALLER
7. Fit a new oil seal with ST.
NOTE:
^ Press-fit until the end of oil seal is 1 mm (0.04 inch) inward from end of carrier.
^ Apply grease between the oil seal lips.
ST 498447120 INSTALLER
8. Press-fit the companion flange with ST1 and ST2.
NOTE: Be careful not to damage the bearing.
ST1 899874100 INSTALLER
ST2 399780104 WEIGHT
9. Install a new self-locking nut. Then tighten it with the ST.
ST 498427200 FLANGE WRENCH
Tightening torque: 181 Nm (18.5 kgf-cm, 134 ft. lbs.)
10. Assembling differential case Install the side gears and pinion mate gears, with their thrust washers and pinion mate shaft, into differential case. (Model without LSD)
NOTE:
^ Apply gear oil on both sides of the washer and on the side gear shaft before installing.
^ Insert the pinion mate shaft into the differential case by aligning the lock pin holes.
1. Measure the side gear backlash.
2. Adjust the backlash as specified by selecting the side gear thrust washer.
3. Check the condition of rotation after applying oil to the gear tooth surfaces and thrust surfaces.
4. After inserting the pinion shaft lock pin into differential case, stake both sides of the hole to prevent pin from falling off.
11. Install the crown gear on differential case.
NOTE: Before installing the bolts, apply Lock Tite to bolt threads.
Lock Tite: THREE BOND 1324 (Part No. 004403042) or equivalent
NOTE: Tighten diagonally while tapping the bolt heads.
12. Press the side bearing into differential case using ST.
ST 398237700 DRIFT
13. Press the side bearing cone into side bearing retainer using ST.
ST 398487700 DRIFT
14. Adjusting side bearing retainer shims
1. The driven gear backlash and side bearing preload can be determined by the side bearing retainer shim thickness.
2. Install the differential case assembly into differential carrier in the reverse order of disassembly.
3. Install the side retainer shims to the right and left retainers from which they were removed.
NOTE: Replace the broken or corroded side retainer shim with a new one of same thickness.
4. Align the arrow mark on differential carrier with the mark on side retainer during installation.
NOTE: Be careful that side bearing outer race is not damaged by bearing roller.
5. Tighten the side bearing retainer bolts.
NOTE: Before tightening the two side bearing retainer bolts, apply Lock Tite to bolt threads.
Lock Tite: THREE BOND 1105 (Part No.004403010) or equivalent
6. Measure the crown gear-to-drive pinion backlash. Set the magnet base on differential carrier. Align the contact point of dial gauge with tooth face of crown gear, and move the crown gear while holding drive pinion still. Read the value indicated on dial gauge.
7. At the same time, measure the total preload of drive pinion. Compared with the resistance when differential case is not installed, if the total preload is not within specification, adjust the thickness of side bearing retainer shims, increasing/reducing by an even amount at a time.
Total preload: 20.7 - 54.4 N (2.1 - 5.5 kgf, 4.7 - 12.2 lbs.)
15. Re-check the crown gear-to-pinion backlash.
16. Check the crown gear runout on its back surface, and make sure that pinion and crown gear rotate smoothly.
17. Checking and adjusting tooth contact of crown gear
1. Apply an even coat of red lead on both sides of three or four teeth on the crown gear. Check the contact pattern after rotating the crown gear several revolutions back and forth until a definite contact pattern appears on the crown gear.
2. When the contact pattern is incorrect, readjust according to the instructions given in "TOOTH CONTACT PATTERN".
NOTE: Be sure to wipe off red lead completely after adjustment is completed.
^ Correct tooth contact
Checking item: Tooth contact pattern is slightly shifted toward to toe side under no-load rotation. (When loaded, contact pattern moves toward heel)
^ Face contact
Checking item: Backlash is too large.
Contact pattern
Corrective action: Increase thickness of drive pinion height adjusting shim in order to bring drive pinion close to crown gear.
^ Flank contact
Checking item: Backlash is too small.
Contact pattern
Corrective action: Reduce thickness of drive pinion height adjusting shim in order to move drive pinion away from crown gear.
^ Toe contact (Inside end contact)
Checking item: Contact area is small.
Contact pattern
Corrective action: Reduce thickness of drive pinion height adjusting shim in order to move drive pinion away from crown gear.
^ Heel contact (Outside end contact)
Checking item: Contact area is small.
Contact pattern
Corrective action: Increase thickness of drive pinion height adjusting shim in order to bring drive pinion close to crown gear.
18. If proper tooth contact is not obtained, once again adjust the drive pinion height by changing RH and LH side bearing retainer shims and the hypoid gear backlash.
19. Remove the side bearing retainers on right and left side.
20. Install new O-rings to side bearing retainers on right and left side.
21. Install the oil seals to side bearing retainers on right and left side.
22. Align the arrow mark on differential carrier with the mark on side retainer during installation.
23. Tighten the side bearing retainer bolts.
24. Install the new gasket and rear cover and tighten the bolts to specified torque.
25. Install the breather cap.
26. Install the drain plug and filler plug.
Tightening torque: 49 Nm (5.0 kgf-cm, 36.2 ft. lbs.)