Assembly
AssemblyDIFFERENTIAL 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.
Backlash between side gear and pinion mate gear (Clearance between side gear thrust washer and differential case): 0.10 - 0.20 mm (0.0039 - 0.0079 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.
Tighten bolts in a cries-cross pattern, lightly tapping bolt head with a hammer.
7. Press-fit side bearing inner cones on differential case with Tool.
Tool number:
A ST33190000 (325523)
B ST33081000 (-)
DIFFERENTIAL CARRIER
1. Press-fit front and rear bearing outer races with Tools.
Tool number:
A ST30611000 (325742-1)
B ST30621000 (325742-5)
C ST30613000 (325742-3)
2. Select drive pinion height adjusting washer.
3. Install drive pinion adjusting washer in drive pinion, and press fit pinion rear bearing inner cone in it, with press and Tool.
Tool number: ST30901000 (326010-01)
4. Place pinion front bearing inner cone in gear carrier.
5. Apply multipurpose grease to cavity at sealing lips of oil seal. Install front oil seal.
Tool number:
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. The threaded portion of drive pinion and pinion nut should be free from oil or grease.
Tool number: KV38108300 (J44195)
9. Turn drive pinion in both directions several times, and measure pinion bearing preload.
Tool number: ST3127SOOO (J25765-A)
Pinion bearing preload (Without front oil seal): 1.2 - 2.0 Nm (12 - 20 kg-cm, 10 - 17 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 are 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.
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: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)
When checking preload, turn drive pinion in both directions several times to set bearing rollers.
Tool number: ST3127SOOO (J25765-A)
Total preload:
P' + [0.3 - 0.4 Nm (3 - 4 kg-cm, 2.6 - 3.5 inch lbs.)]
P': Drive pinion preload
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.