Adjustment and Selection of Adjusting Washers

ADJUSTMENT AND SELECTION OF ADJUSTING WASHERS

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Differential Side Gear Clearance
^ Assemble the differential parts if they are disassembled.





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.
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 RFD-18, "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.
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 RFD-18, "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.





13. Remove the J-34309 differential shim selector tool from the final drive housing. Then disassemble to retrieve the pinion bearings.