Assembly
Drive Pinion Assembly
1. Install front bearing outer race (1) and rear bearing outer race (2) 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.
^ Never 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 (2) to drive pinion. Press pinion rear bearing inner race (1) to it, using drift.
Tool number A: ST30901000 (J-26010-01)
CAUTION:
^ Pay attention to the direction of pinion height adjusting washer. (Assemble as shown in the figure.)
^ Never reuse pinion rear bearing inner race.
4. Assemble collapsible spacer to drive pinion.
CAUTION: Never 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: Never reuse pinion front bearing inner race.
7. Using suitable spacer (A), 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 A: ST30720000 (J-25405)
CAUTION:
^ Never reuse oil seal.
^ When installing, never incline oil seal.
^ Apply multi-purpose grease onto oil seal lips, and gear oil onto the circumference of oil seal.
9. 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).
10. Apply anti-corrosion oil to the thread and seat of drive pinion lock nut, and temporarily tighten drive pinion lock nut to drive pinion.
CAUTION: Never reuse drive pinion lock nut.
11. Adjust to the drive pinion lock nut tightening torque and pinion bearing preload torque.
Tool number A: ST3127S000 (J-25765-A)
Drive pinion lock nut tightening torque: 147 - 323 Nm (15 - 32 kg-m, 109 - 238 ft-lb)
Drive pinion bearing preload: 2.65 - 3.23 Nm (0.27 - 0.32 kg-m, 24 - 28 in-lb)
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. Never loosen drive pinion lock nut 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: Never 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: Never 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.
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 bolts 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: Never 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 marks 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:
^ Never reuse oil seal.
^ When installing, never 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.
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 in)