Assembly

DIFFERENTIAL ASSEMBLY


A/T : Assembly






1. Install side gear thrust washer with the same thickness as the ones installed prior to disassembly or reinstall the old ones on the side gear.





2. Install side gear and thrust washer into differential case B.

CAUTION:
Make sure that the circular clip is installed to side gear.
3. Install pinion mate assembly (pinion mate shaft, pinion mate gears and pinion mate thrust washers) into differential case B.

CAUTION:
Install the pinion mate shaft groove side to side gear.





4. Install viscous coupling into differential case B.
5. Install side gear thrust washer with the same thickness as the ones installed prior to disassembly or reinstall the old ones on the viscous coupling.





6. Align the matching marks and install differential case A into differential case B.
7. Measure side gear end play. If necessary, select the appropriate side gear thrust washer.
a. Place differential assembly so that right side gear is on the upper side.





b. Measure the clearance between right side gear back and differential case using feeler gauge, while rotating right side gear with a suitable tool attached to splines.

Standard
Side gear back clearance : Refer to DLN-295, "Differential Side Gear Clearance". Differential Side Gear Clearance

CAUTION:
- Never place feeler gauge at groove side of differential case.
- To prevent side gear from tilting, insert feeler gauges with the same thickness from both sides.
c. If the back clearance is outside the specification, use a thicker/thinner side gear thrust washer to adjust.

When the back clearance is large: Use a thicker thrust washer.
When the back clearance is small: Use a thinner thrust washer.

CAUTION:
- Adjust the clearance with the left side gear thrust washer only.
- Only one side gear thrust washer can be selected.





8. Align the matching mark of differential case with the mark of drive gear, then place drive gear.





9. Apply thread locking sealant into the thread hole of drive gear.
Use Genuine High Strength Thread Locking Sealant or equivalent. Fluid Type Specifications.

CAUTION:
Clean and degrease drive gear back and threaded holes sufficiently.
10. Install the drive gear to differential case.

CAUTION:
Align the matching marks of differential case and drive gear.





11. Tighten the mounting bolts with the following procedure.

CAUTION:
Apply anti-corrosion oil to the thread and seat of mounting bolts.
a. Tighten the bolts in a crisscross fashion to the specified torque.

Drive gear mounting bolts tightening torque : 78.5 Nm (8.0 kg-m, 58 ft-lb)

b. Tighten the bolts additionally at the specified angle.
Drive gear mounting bolts tightening angle : 31 to 36 degree

CAUTION:
Check the tightening angle using the angle wrench [SST: KV10112100(BT-8653-A)]. Never make judgment by visual inspection.





12. Press side bearing inner races to differential case, using the drift
(A) [SST: KV38100300 (J-25523)] and the base (B) [SST:
ST33061000 (J-8107-2)].

CAUTION:
Never reuse side bearing inner race.





13. Install differential case assembly with side bearing outer races into gear carrier.
14. Measure side bearing preload. If necessary, select the appropriate side bearing adjusting washers. Adjustment.





15. Insert selected left and right side bearing adjusting washers in place between side bearings and gear carrier.





16. Align matching marks on bearing cap with that on gear carrier.
17. Install bearing caps and tighten bearing cap mounting bolts.





18. Using the drift [SST: KV38100200 (J-26233)], drive side oil seals until it becomes flush with the case end.

CAUTION:
- Never reuse oil seal.
- When installing, never incline oil seal.
- Apply multi-purpose grease onto oil seal lips, and gear oil onto the circumference of oil seal.
19. Check and adjust drive gear runout, tooth contact, drive gear to drive pinion backlash, and total preload torque. Adjustment.
Recheck above items. Readjust the above description, if necessary.





20. Apply sealant to mating surface of rear cover.
Use Genuine Silicone RTV or equivalent. Fluid Type Specifications.

CAUTION:
Remove old sealant adhering to mounting surfaces. Also remove any moisture, oil, or foreign material adhering to application and mounting surfaces.
21. Install rear cover on gear carrier and tighten mounting bolts.





22. Install side flange with the following procedure.
a. Attach the protector [SST: KV38107900 (J-39352)] to side oil seal.
b. After the side flange is inserted and the serrated part of side gear has engaged the serrated part of flange, remove the protector.
c. Put a suitable drift on the center of side flange, then drive it until sound changes.

NOTE:
When installation is completed, driving sound of the side flange turns into a sound that seems to affect the whole final drive.





d. Confirm that the dimension of the side flange (1) installation
(Measurement A) in the figure comes into the following.

Measurement "A" : 326 - 328 mm (12.83 - 12.91 in)