Installation of Differential Case Assembly

INSTALLATION OF DIFFERENTIAL CASE ASSEMBLY
1. Select side bearing adjusting washer.





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





3. Insert original left and right side bearing adjusting washers in place between side bearings and carrier.





4. Align matching mark on bearing cap with that on gear carrier.
5. Install the side bearing cap.
6. Install side oil seal.
Tool number: KV38100200 (J26233)





7. Measure drive gear-to-drive pinion backlash with a dial indicator at several point.
Drive gear to drive pinion backlash: 0.10 - 0.15 mm (0.0039 - 0.0059 inch)
^ It backlash is too small, adjustment of washer thickness is required. Decrease thickness of left shim and increase thickness of right by the same amount. If backlash is too great, reverse the above procedure.
^ Never change the total amount of washers as it will change the bearing preload.





8. Check total preload with tool.
Tool number: ST3127S000 (See J25765-A)
When checking preload, turn drive pinion in both directions several times to seat bearing rollers correctly.
Total preload: 2.84- 3.75 Nm (0.29 - 0.38 kg-m, 26 - 33 inch lbs.)
^ If preload is too great, remove the same amount of washer to each side.
^ If preload is too small, add the same amount of washer to each side.

Never add or remove a different number of washers for each side. Difference in number of washers will change drive gear to drive pinion backlash.
9. Recheck drive gear to drive pinion backlash. Increase or decrease in thickness of shims will cause change to drive gear to pinion backlash.
^ Check whether the backlash varies excessively in different places. Foreign matter may be caught between the drive gear and the differential case causing the trouble. The backlash can vary greatly even when the drive gear runout is within a specified range. In that case, replace the hypoid gear set or differential case.





10. Check runout of drive gear with a dial indicator.
Drive gear runout limit: 0.05 mm (0.0020 inch) or less
11. Check tooth contact.





12. Install rear cover. Apply liquid sealant to rear cover side and install gear carrier.