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 in) 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 FFD-39, "Inspection and Adjustment". Inspection and Adjustment
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: ST30611000 (J-25742-1)
B: KV31103000 (J-38982)
CAUTION:
^ At first, using a hammer, tap bearing outer race until it becomes flat to side retainer.
^ Never reuse side bearing outer race.
3. Press-fit side bearing outer race into gear carrier with tool.
Tool number
A: ST30611000 (J-25742-1)
B: KV31103000 (J-38982)
CAUTION:
^ At first, using a hammer, tap bearing outer race until it becomes flat to gear carrier.
^ Never 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: Never 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: 34.2 - 39.2 N (3.5 - 4.0 kg, 7.7 - 8.8 lb) 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 FFD-39, "Inspection and Adjustment". Inspection and Adjustment
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. Use the formula below to calculate pinion height adjusting washer thickness.
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. If impossible 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
Pinion Bearing Preload
^ Assemble the drive pinion parts if they are disassembled. Refer to "Drive Pinion Assembly".
1. Make sure all parts are clean. Also, make sure the bearings are well lubricated with gear oil.
2. Install companion flange (1).
NOTE: When reusing drive pinion, align the matching mark (B) of drive pinion with the matching mark (A) of companion flange, and then install companion flange (1).
3. Temporarily tighten removed drive pinion lock nut to drive pinion.
NOTE: Use removed drive pinion lock nut only for the preload measurement.
4. Rotate drive pinion at least 20 times to check for smooth operation of the bearing.
5. Tighten to drive pinion lock nut, while adjust pinion bearing pre load torque.
Tool number A: ST3127S000 (J-25765-A)
Drive pinion lock nut tightening torque: 127.4 - 245.0 Nm (13.0 - 25.0 kg-m, 94 - 181 ft-lb)
Pinion bearing preload: 0.78 - 1.57 Nm (0.08 - 0.16 kg-m, 7 - 13 in-lb)
CAUTION:
^ Adjust to the lower limit of the drive pinion lock nut tightening torque first.
^ After adjustment, rotate drive pinion back and forth 2 to 3 times to check for unusual noise, rotation malfunction, and other malfunctions.
6. If the pinion bearing preload torque is outside the specification use a thicker/thinner drive pinion bearing adjusting washer and drive pinion adjusting washer to adjust. Refer to FFD-39, "Inspection and Adjustment". Inspection and Adjustment
When the preload torque is large:
Decrease the drive pinion bearing adjusting washer and drive pinion adjusting washer thickness.
When the preload is small:
Increase the drive pinion bearing adjusting washer and drive pinion adjusting washer thickness.
7. Remove companion flange, after adjustment.