Assembly Inspection and Adjustment

ASSEMBLY INSPECTION AND ADJUSTMENT
^ Before inspection and adjustment, drain gear oil.

Total Preload Torque
1. Secure final drive assembly onto an attachment.
Tool number A: KV38100800 (J-25604-01)
2. Remove side flanges.
3. Rotate drive pinion back and forth 2 to 3 times to check for unusual noise and rotation malfunction.





4. Rotate drive pinion at least 20 times to check for smooth operation of the bearing.
5. Measure total preload with the preload gauge.
Tool number A: ST3127S000 (J-25765-A)
Total preload torque: 2.85 - 3.75 Nm (0.29 - 0.38 kg-m, 26 - 33 inch lbs.)

NOTE: Total preload torque = Pinion bearing preload torque + Side bearing preload torque

^ If measured value is out of the specification, disassemble it to check and adjust each part. Adjust the pinion bearing preload and side bearing preload. Adjust the pinion bearing preload first, then adjust the side bearing preload.
When the preload torque is large
On pinion bearings: Replace the collapsible spacer.
On side bearings: Use thinner side bearing adjusting washers by the same amount to each side.
When the preload is small
On pinion bearings: Tighten the drive pinion lock nut.
On side bearings: Use thicker side bearing adjusting washers by the same amount to each side.

Drive Gear Runout
1. Remove rear cover.





2. Fit a dial indicator to the drive gear back face.
3. Rotate the drive gear to measure runout.
Runout limit: 0.05 mm (0.0020 inch)
^ If the runout is outside of the repair limit, check drive gear assembly condition; foreign material may be caught between drive gear and differential case, or differential case or drive gear may be deformed, etc.

CAUTION: Replace drive gear and drive pinion gear as a set.

Tooth Contact
1. Remove rear cover.





2. Apply red lead to drive gear.
Backlash: 0.10 - 0.15 mm (0.0039 - 0.0059 inch)

CAUTION: Apply red lead to both the faces of 3 to 4 gears at 4 locations evenly spaced on drive gear.





3. Rotate drive gear back and forth several times, check drive pinion gear to drive gear tooth contact.

CAUTION: Check tooth contact on drive side and reverse side.








4. If tooth contact is improperly adjusted, follow the procedure below to adjust the pinion height (dimension X).





^ If the tooth contact is near the face (face contact), or near the heel (heel contact), thicken pinion height adjusting washers to move drive pinion closer to drive gear.





^ If the tooth contact is near the flank (flank contact), or near the toe (toe contact), thin pinion height adjusting washers to move drive pinion farther from drive gear.

Backlash
1. Remove rear cover.





2. Fit a dial indicator to the drive gear face to measure the backlash.
Backlash: 0.10 - 0.15 mm (0.0039 - 0.0059 inch)
^ If the backlash is outside of the specified value, change the thickness of side bearing adjusting washer.
When the backlash is large: Make drive gear back side adjusting washer thicker, and drive gear tooth side adjusting washer thinner by the same amount.
When the backlash is small: Make drive gear back side adjusting washer thinner, and drive gear tooth side adjusting washer thicker by the same amount.

CAUTION: Do not change the total amount of washers as it will change the bearing preload.

Companion Flange Runout





1. Fit a test indicator to the inner side of companion flange (socket diameter).
2. Rotate companion flange to check for runout.
Runout limit: 0.08 mm (0.0031 inch)
3. If the runout value is outside the runout limit, follow the procedure below to adjust.
a. Check for runout while changing the phase between companion flange and drive pinion by 90° step, and search for the position where the runout is the minimum.
b. If the runout value is still outside of the limit after the phase has been changed, possible cause will be an assembly malfunction of drive pinion and pinion bearing and malfunction of pinion bearing. Check for these items and repair if necessary.
c. If the runout value is still outside of the limit after the check and repair, replace companion flange.