Disassembly and Assembly
DISASSEMBLY
Differential Assembly
1. Drain gear oil, if necessary.
2. Remove side flange.
3. Remove rear cover mounting bolts.
4. Remove rear cover to insert the seal cutter between gear carrier and rear cover.
Tool number: KV10111100 (J-37228)
CAUTION:
^ Be careful not to damage the mating surface.
^ Do not insert flat-bladed screwdriver, this way damage the mating surface.
5. Using two 45 mm (1.77 inch) spacers, mount carrier on the attachment.
Tool number: KV38100800 (J-25604-01)
6. For proper reinstallation, paint matching marks on one side of the bearing cap.
CAUTION:
^ For matching mark, use paint. Do not damage bearing caps and gear carrier.
^ Bearing caps are line board during manufacture. The matching marks are used to reinstall them in their original positions.
7. Remove bearing caps.
8. Lift differential case assembly out with a suitable tool.
^ Keep side bearing outer races together with inner race. Do not mix them up. Also, keep side bearing adjusting washers together with bearings.
9. Remove side bearing inner race. To prevent damage to bearing, engage puller jaws in groove.
Tool number
A: ST33051001 (J-22888-20)
B: ST33061000 (J-8107-2)
CAUTION:
^ To prevent damage to the side bearing and drive gear, place copper plates between these parts and vise.
^ It is not necessary to remove side bearing inner race except it is replaced.
10. For proper reinstallation, paint matching mark on one differential case assembly.
CAUTION: For matching mark, use paint. Do not damage differential case and drive gear.
11. Remove drive gear mounting bolts.
12. Tap drive gear off differential case assembly with a soft hammer.
CAUTION: Tap evenly all around to keep drive gear from bending.
13. Remove lock pin of pinion mate shaft with a punch from drive gear side.
14. Remove pinion mate shaft.
15. Turn pinion mate gear, then remove pinion mate gear, pinion mate thrust washer, side gear and side gear thrust washer from differential case.
Drive Pinion Assembly
1. Remove differential assembly. Refer to Differential Assembly.
2. Remove drive pinion lock nut with the flange wrench.
Tool number: KV40104000 ( - )
3. Put matching mark on the end of drive pinion. The matching mark should be in line with the matching mark A on companion flange.
CAUTION: For matching mark, use paint. Do not damage companion flange and drive pinion.
NOTE: The matching mark A on the final drive companion flange indicates the maximum vertical runout position. When replacing companion flange, matching mark is not necessary.
4. Remove companion flange using the suitable puller.
5. Press drive pinion assembly out of gear carrier.
CAUTION: Do not drop drive pinion assembly.
6. Remove front oil seal.
7. Remove side oil seal.
8. Remove pinion front bearing inner race.
9. Remove collapsible spacer.
10. Remove pinion rear bearing inner race and drive pinion height adjusting washer with the replacer.
Tool number: ST30031000 (J-22912-01)
11. Tap pinion front/rear bearing outer races uniformly a brass rod or equivalent to removed.
CAUTION: Be careful not to damage gear carrier.
INSPECTION AFTER DISASSEMBLY
Clean up the disassembled parts. Then, inspect if the parts are worn or damaged. If so, follow the measures below.
ADJUSTMENT AND SELECTION OF ADJUSTING WASHERS
Differential Side Gear Clearance
^ Assemble the differential parts if they are disassembled. Refer to Differential Assembly.
1. Place differential case straight up so that side gear to be measured comes upward.
2. Using feeler gauge, measure the clearance between side gear back and differential case at 3 different points, while rotating side gear. Average the 3 readings, and then measure the clearance of the other side as well.
Side gear back clearance specification: 0.2 mm (0.008 inch) or less.
(Each gear should rotate smoothly without excessive resistance during differential motion.)
CAUTION: To prevent side gear from tilting, insert feeler gauges with the same thickness from both sides.
3. If the back clearance is outside the specification, use a thicker/ thinner side gear thrust washer to adjust. Refer to Side Gear Thrust Washer.
When the back clearance is large: Use a thicker thrust washer.
When the back clearance is small: Use a thinner thrust washer.
CAUTION: Select a side gear thrust washer for right and left individually.
Side Bearing Preload
^ Selecting carrier side bearing adjusting washers is required for successful completion of this procedure.
1. Make sure all parts are clean. Also, make sure the bearings are well lubricated with gear oil.
2. Place the differential case, with side bearings and bearing races Installed, Into gear carrier.
3. Insert left and right original side bearing adjusting washers in place between side bearings and gear carrier.
4. Install bearing caps in their correct locations and tighten bearing cap mounting bolts to the specified torque. Refer to COMPONENTS.
5. Turn the carrier several times to seat the bearings.
6. Measure the turning torque of the carrier at the drive gear mounting bolts with a spring gauge.
Tool number: - (J-8129)
Specification: 34.2 - 39.2 N (3.5 - 4.0 kg, 7.7 - 8.8 lbs.) of pulling force at the drive gear bolt
7. If the turning torque is outside the specification, use a thicker/thinner side bearing adjusting washer to adjust. Refer to Side Bearing Adjusting Washer.
^ If the turning torque is less than the specified range: Use a thicker thrust washer.
^ If the turning torque is greater than the specification: Use a thinner thrust washer.
CAUTION: Select a side bearing adjusting washer for right and left individually.
8. Record the total amount of washer thickness required for the correct carrier side bearing preload.
Pinion Gear Height
1. Make sure all parts are clean and that the bearings are well lubricated.
2. Assemble the pinion gear bearings into the differential shim selector tool.
Tool number: - (J-34309)
^ Pinion front bearing; make sure the J-34309-3 pinion front bearing seat is secured tightly against the J-34309-2 gauge anvil. Then turn the pinion front bearing pilot, J-34309-5, to secure the bearing in its proper position.
^ Pinion rear bearing; the pinion rear bearing pilot, J-34309-8, is used to center the pinion rear bearing only. The pinion rear bearing locking seat, J-34309-4, is used to lock the bearing to the assembly.
^ Installation of J-34309-9 and J-34309-16; place a suitable 2.5 mm (0.098 inch) thick plain washer between J-34309-9 and J-34309-16. Both surfaces of J-34309-9 and J-34309-16 must be parallel with a clearance of 2.5 mm (0.098 inch).
3. Install the pinion rear bearing inner race into gear carrier. Then place the pinion preload shim selector tool, J-34309-1, gauge screw assembly.
4. Assemble the pinion front bearing inner race and the J-34309-2 gauge anvil. Assemble them together with the J-34309-1 gauge screw in gear carrier. Make sure that the pinion height gauge plate, J-34309-16, will turn a full 360 degrees. Tighten the two sections together by hand.
5. Turn the assembly several times to seat the bearings.
6. Measure the turning torque at the end of the J-34309-2 gauge anvil using preload gauge.
Tool number: ST3127S000 (J-25765-A)
Turning torque specification: 1.0 1.3 Nm (0.11 - 0.13 kg-m, 9 - 11 inch lbs.)
7. Place the J-34309-11 R200A pinion height adapter onto the gauge plate and tighten it by hand.
CAUTION: Make sure all machined surfaces are clean.
8. Position the side bearing discs, J-25269-4, and arbor firmly into the side bearing bores. Install the bearing caps and tighten bearing cap mounting bolts to the specified torque. Refer to COMPONENTS.
9. Select the correct standard pinion height adjusting washer thickness. Select by using a standard gauge of 3 mm (0.12 inch) and your J-34309-101 feeler gauge. Measure the distance between the J-34309-11 pinion height adapter including the standard gauge and the arbor.
10. Write down exact measurement (the value of feeler gauge).
11. Correct the pinion height washer size by referring to the pinion head number.
There are two numbers painted on the drive pinion. The first one refers to the drive pinion and drive gear as a matched set. This number should be the same as the number on the drive gear. The second number is the pinion head height number. It refers to the ideal pinion height from standard for quietest operation. Use the following chart to determine the correct pinion height washer.
12. Select the correct pinion height adjusting washer. Refer to Pinion Height Adjusting Washer.
13. Remove the J-34309 differential shim selector tool from the final drive housing. Then disassemble to retrieve the pinion bearings.
ASSEMBLY
Drive Pinion Assembly
1. Install front and rear bearing outer races using drifts.
Tool number
A: ST30720000 (J-25405)
B: KV40105230 ( - )
C: ST30611000 (J-25742-1)
D: ST30613000 (J-25742-3)
CAUTION:
^ At first, using a hammer, tap bearing outer race until it becomes flat to gear carrier.
^ Do not reuse pinion front and rear bearing outer race.
2. Select drive pinion height adjusting washer. Refer to Pinion Gear Height.
3. Install selected drive pinion height adjusting washer to drive pinion. Press pinion rear bearing inner race to it, using drift.
Tool number: ST30901000 (J-26010-01)
CAUTION:
^ Pay attention to the direction of pinion height adjusting washer. (Assemble as shown in the figure.)
^ Do not reuse pinion rear bearing inner race.
4. Assemble collapsible spacer to drive pinion.
CAUTION: Do not reuse collapsible spacer.
5. Apply gear oil to pinion rear bearing, and assemble drive pinion into gear carrier.
6. Apply gear oil to pinion front bearing, and assemble pinion front bearing inner race to drive pinion assembly.
CAUTION: Do not reuse pinion front bearing inner race.
7. Using suitable spacer, press the pinion front bearing inner race to drive pinion as far as drive pinion nut can be tightened.
8. Using the drift, install front oil seal as shown in figure.
Tool number: ST30720000 (J-25405)
CAUTION:
^ Do not reuse oil seal.
^ When installing, do not incline oil seal.
^ Apply multi-purpose grease onto oil seal lips, and gear oil onto the circumference of oil seal.
9. Install companion flange.
NOTE: When reusing drive pinion, align the matching mark of drive pinion with the matching mark A of companion flange, then install companion flange.
10. Apply gear oil to the thread and seat of drive pinion lock nut, and temporarily tighten drive pinion lock nut to drive pinion.
CAUTION: Do not reuse drive pinion lock nut.
11. Adjust to the drive pinion lock nut tightening torque and pinion bearing preload torque.
Tool number
A: KV40104000 ( - )
B: ST3127S000 (J-25765A)
Drive pinion lock nut tightening torque: 147 - 323 Nm (15 - 32 kg-m, 109 - 238 ft. lbs.)
Drive pinion bearing preload: 2.65 - 3.23 Nm (0.27 - 0.32 kg-m, 24 28 inch lbs.)
CAUTION:
^ Adjust to the lower limit of the drive pinion lock nut tightening torque first.
^ If the preload torque exceeds the specified value, replace collapsible spacer and tighten it again to adjust. Do not loosen drive pinion locknut to adjust the preload torque.
^ After adjustment, rotate drive pinion back and forth 2 to 3 times to check for unusual noise, rotation malfunction, and other malfunctions.
12. Install differential case assembly. Refer to Differential Assembly.
CAUTION: Do not install rear cover yet.
13. Check and adjust drive gear runout, tooth contact, drive gear to drive pinion backlash, and companion flange runout. Refer to Drive Gear Runout, Tooth Contact, Backlash, Companion Flange Runout. Recheck above items. Readjust the above description, if necessary.
14. Check total preload torque. Refer to Total Preload Torque.
15. Install rear cover. Refer to Differential Assembly.
Differential Assembly
1. Install side gear thrust washers with the same thickness as the ones installed prior to disassembly or reinstall the old ones on the side gears.
2. Install side gears and thrust washers into differential case.
CAUTION: Make sure that the circular clip is installed to side gears.
3. Align 2 pinion mate gears in diagonally opposite positions, then rotate and install them into differential case after installing thrust washer to pinion mate gear.
4. Align the lock pin holes on differential case with shaft, and install pinion mate shaft.
5. Measure side gear end play. If necessary, select the appropriate side gear thrust washers. Refer to Differential Side Gear Clearance.
6. Drive a lock pin into pinion mate shaft, using a punch. Make sure lock pin is flush with differential case.
CAUTION: Do not reuse lock pin.
7. Align the matching mark of differential case with the mark of drive gear, then place drive gear.
8. Apply thread locking sealant into the thread hole of drive gear.
^ Use Genuine High Strength Thread Locking Sealant or equivalent. Refer to RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS.
CAUTION: Drive gear back and threaded holes shall be cleaned and degreased sufficiently.
9. Install drive gear on the mounting bolts, and then tighten to the specified torque. Refer to COMPONENTS.
CAUTION:
^ Tighten bolts in a crisscross fashion.
^ After tightening the bolt to the specified torque, tighten the bolts additionally by turning the bolts 31 to 36 degrees.
10. Press side bearing inner races to differential case, using the drift and the base.
Tool number
A: KV38100300 (J-25523)
B: ST33061000 (J-8107-2)
CAUTION: Do not reuse side bearing inner race.
11. Install differential case assembly with side bearing outer races into gear carrier.
12. Measure side bearing preload. If necessary, select the appropriate side bearing adjusting washers. Refer to Side Bearing Preload.
13. Insert selected left and right side bearing adjusting washers in place between side bearings and gear carrier.
14. Align matching mark on bearing cap with that on gear carrier.
15. Install bearing caps and tighten bearing cap mounting bolts to the specified torque. Refer to COMPONENTS.
16. Using the drift, drive side oil seals until it becomes flush with the case end.
Tool number: KV38100200 (J-26233)
CAUTION:
^ Do not reuse oil seal.
^ When installing, do not incline oil seal.
^ Apply multi-purpose grease onto oil seal lips, and gear oil onto the circumference of oil seal.
17. Check and adjust drive gear runout, tooth contact, drive gear to drive pinion backlash, and total preload torque. Refer to Drive Gear Runout, Tooth Contact, Backlash, Total Preload Torque Recheck above items. Readjust the above description, if necessary.
18. Apply sealant to mating surface of rear cover.
^ Use Genuine Silicone RTV or equivalent. Refer to RECOMMENDED CHEMICAL PRODUCTS AND SEAL.
CAUTION: Remove old sealant adhering to mounting surfaces. Also remove any moisture, oil, or foreign material adhering to application and mounting surfaces.
19. Install rear cover on gear carrier and tighten mounting bolts with the specified torque. Refer to COMPONENTS.
20. Install side flange with the following procedure.
a. Attach the protector to side oil seal.
Tool number: KV38107900 (J-39352)
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 which seems to affect the whole final drive.
d. Confirm that the dimension of the side flange installation (Measurement A) in the figure comes into the following.
Measurement A: 326 - 328 mm (12.83 - 12.91 inch)