Part 1
Part 1:
Part 2:
Part 1:
Part 2:
Disassembly and Assembly
DISASSEMBLY
Side Shaft Assembly
1. Hold extension tube retainer with puller, then press out side shaft using a press.
2. Remove side shaft oil seal from extension tube retainer with a flat blade screwdriver.
3. Remove side shaft bearing from extension tube retainer.
4. Remove O-ring from extension tube retainer.
5. Remove dust sealed from side shaft.
Differential Assembly
1. Drain gear oil, if necessary.
2. Remove carrier cover mounting bolts.
3. Remove carrier cover to insert the seal cutter between gear carrier and carrier 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.
4. Remove side retainer mounting bolts.
5. Remove side retainer.
6. Remove side bearing adjusting shim.
7. Remove O-ring from side retainer.
8. Remove differential case assembly from gear carrier.
9. Remove side oil seal (right side) from side retainer.
10. Remove side bearing outer race with puller.
Tool number: KV381054S0 (J-34286)
11. Remove O-ring from gear carrier.
12. Remove side oil seal (left side) from gear carrier.
13. Remove side bearing outer race with puller.
Tool number: KV381054S0 (J-34286)
14. 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.
15. 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.
16. Remove drive gear mounting bolts.
17. Tap drive gear off differential case assembly with a soft hammer.
CAUTION: Tap evenly all around to keep drive gear from bending.
18. Remove lock pin of pinion mate shaft with a punch from drive gear side.
19. Remove pinion mate shaft.
20. Turn pinion mate gear, then remove pinion mate gears, pinion mate thrust washers, side gears and side gear thrust washers from differential case.
Drive Pinion Assembly
1. Remove differential assembly. Refer to Differential Assembly.
2. Remove drive pinion lock nut with a flange wrench.
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 pinion front bearing inner race.
8. Remove drive pinion bearing adjusting washer and drive pinion adjusting washer.
9. Remove pinion rear bearing inner race and drive pinion height adjusting washer with replacer.
Tool number: ST30031000 (J-22912-01)
10. 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 (SHIMS)
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
1. Make sure all parts are clean. Also, make sure the bearings are well lubricated with gear oil.
2. Press-fit side bearing outer race into side retainer with tool.
Tool number
A: KV31103000 ( - )
B: ST30611000 (J-25742-1)
CAUTION:
^ At first, using a hammer, tap bearing outer race until it becomes flat to side retainer.
^ Do not reuse side bearing outer race.
3. Press-fit side bearing outer race into gear carrier with tool.
Tool number
A: KV31103000 ( - )
B: ST30611000 (J-25742-1)
CAUTION:
^ At first, using a hammer, tap bearing outer race until it becomes flat to gear carrier.
^ Do not reuse side bearing outer race.
4. Place the differential case assembly into gear carrier.
5. Install side bearing adjusting shim before disassembling or shim which thickness is the same as the one before disassembling.
6. Install side retainer assembly to gear carrier.
CAUTION: Do not install O-ring.
7. Install side retainer mounting bolts to the specified torque. Refer to COMPONENTS (VQ35DE MODELS), COMPONENTS (VK45DE MODELS).
8. Measure the turning torque of the gear carrier at the drive gear mounting bolts with a spring gauge.
Tool number: - (J-8129)
Specification: 0.78 - 1.08 N (0.08 - 0.11 kg, 0.57 - 0.80 lbs.) of pulling force at the drive gear bolt
9. If the turning torque is outside the specification, use a thicker/ thinner side bearing adjusting shim to adjust. Refer to Side Bearing Adjusting Shim.
^ If the turning torque is less than the specified range: Decrease the side bearing adjusting shim thickness.
^ If the turning torque is greater than the specification: Increase the side bearing adjusting shim thickness.
10. Record the total amount of shim thickness required for the correct carrier side bearing preload.
Pinion Gear Height
If the hypoid gear set has been replaced, select the pinion height adjusting washer.
1. Substitute these values into the equation to calculate the thickness of the washer.
Washer selection equation: T = T0 + (T1 - t2)
T: Correct washer thickness
T0: Removed washer thickness
t1: Old drive pinion head letter H x 0.01 (H: machined tolerance 1/100 mm x 100)
t2: New drive pinion head letter H x 0.01 (H: machined tolerance 1/100 mm x 100)
Example:
T = 3.21 + [(2 x 0.01) - (1 x 0.01)] = 3.24
T0:3.21
t1: +2
t2: -1
2. Select the proper pinion height adjusting washer. Refer to Pinion Height Adjusting Washer.
If you cannot find the desired thickness of washer, use washer with thickness closest to the calculated value.
Example:
Calculated value... T = 3.22 mm
Used washer... T = 3.21 mm