Part 2

REAR FINAL DRIVE


Disassembly and Assembly (continued)

Gear Carrier
- If any wear or cracks are found on the contact sides of gear carrier, replace with new one.

Companion Flange
- If any chips (about 0.1mm, 0.004 in) or other damage on the companion flange surface which contacts the front oil seal lips are found, replace with new one.

ADJUSTING AND SELECTING WASHERS

Side Gear Back Clearance
- Assemble the differential parts if they are disassembled.





1. Place the differential case straight up so that the side gear to be measured is upward.





2. Using feeler gauges, measure the clearance between the side gear back and differential case at three different points, while rotating the side gear. Average the three readings to calculate the clearance. (Measure the clearance of the other side as well.)

Side gear back clearance : Refer to DLN-270, "Inspection and Adjustment" Inspection and Adjustment

- If the side gear back clearance is outside of the specification, use a thicker or thinner side gear thrust washer to adjust. Inspection and Adjustment.

If the side gear back clearance is greater than specification:
Use a thicker side gear thrust washer.
If the side gear back clearance is less than specification:
Use a thinner side gear thrust washer.


CAUTION:
- Insert feeler gauges with the same thickness on both sides to prevent side gear from tilting.
- Each gear should rotate smoothly without excessive resistance during differential motion.
- Select a side gear thrust washer for right and left individually.

NOTE:
Side gear back clearance is clearance between side gear and differential case for adjusting side gear backlash.

Side Bearing Preload Torque
- A selection of side bearing adjusting washers is required for successful completion of this procedure.





1. Apply differential gear oil to the side bearings, and install the differential case assembly with the side bearing outer races into the gear carrier.

CAUTION:
Do not reuse side bearing outer race when replacing side bearing inner race (replace as a set).





2. Insert the left and right original side bearing adjusting washers in place between side bearings and gear carrier.





3. Align the matching mark on the side bearing cap with the matching mark on the gear carrier.
4. Install the side bearing caps and tighten the side bearing cap bolts to the specified torque.
5. Turn the differential assembly several times to seat the side bearings.





6. To determine side bearing preload torque, measure the pulling force of the differential assembly at the drive gear bolt using
Tool.

Tool number : - (J-8129)

Specification : Refer to DLN-270, "Inspection and Adjustment" Inspection and Adjustment

NOTE:
If pulling force of the differential assembly at the drive gear bolt is within specification, side bearing preload torque will also be within specification. Inspection and Adjustment.





7. If the pulling force is outside the specification, use a thicker or thinner side bearing adjusting washer to adjust. Inspection and Adjustment.

If the pulling force is less than the specification:
Use a thicker side bearing adjusting washer.
If the pulling force is greater than the specification:
Use a thinner side bearing adjusting 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 side bearing preload torque.

ASSEMBLY

Drive Pinion Assembly





1. Install the drive pinion front and rear bearing outer races using
Tools.

Tool number
A: ST15310000 ( - )
B: ST35325000 ( - )
C: ST30621000 ( - )


CAUTION:
Do not reuse drive pinion front and rear bearing outer race.
2. Select a drive pinion height adjusting washer. Inspection and Adjustment.





3. Install the selected drive pinion height adjusting washer to the drive pinion. Press the drive pinion rear bearing inner race to it using Tool.

Tool number : ST30022000 ( - )


CAUTION:
- Install the drive pinion height adjusting washer in the proper direction as shown.
- Do not reuse drive pinion rear bearing inner race.





4. Assemble the collapsible spacer to the drive pinion.

CAUTION:
Do not reuse collapsible spacer.
5. Apply differential gear oil to the drive pinion rear bearing, and install the drive pinion assembly to the gear carrier.
6. Apply differential gear oil to the drive pinion front bearing, and install the drive pinion front bearing inner race to the drive pinion assembly.

CAUTION:
Do not reuse drive pinion front bearing inner race.





7. Press the drive pinion front bearing inner race to the drive pinion as far as drive pinion lock nut can be tightened using suitable spacer.





8. Apply multi-purpose grease to the lips of the new front oil seal.
Then drive the new front oil seal in evenly until it becomes flush with the gear carrier using Tool.

Tool number : ST15310000 ( - )


CAUTION:
- Do not reuse front oil seal.
- Do not incline the new front oil seal when installing.
- Apply multi-purpose grease to the lips of the new front oil seal.
9. Install the companion flange to the drive pinion while aligning the matching marks.





10. Apply anti-corrosive oil to the threads of the drive pinion and the seating surface of the new drive pinion lock nut. Then adjust the drive pinion lock nut tightening torque using suitable tool (A), and check the drive pinion bearing preload torque using Tool
(B).

Tool number B: ST3127S000 (J-25765-A)

Drive pinion bearing preload torque : Refer to DLN-270, "Inspection and Adjustment" Inspection and Adjustment


CAUTION:
- Do not reuse drive pinion lock nut.
- Apply anti-corrosive oil to the threads of the drive pinion and the seating surface of the new drive pinion lock nut.
- Adjust the drive pinion lock nut tightening torque to the lower limit first. Do not exceed the drive pinion lock nut specified torque.
- If the drive pinion bearing preload torque exceeds the specified value, replace collapsible spacer and tighten it again to adjust. Do not loosen drive pinion lock nut to adjust the drive pinion bearing preload torque.
- After adjustment, rotate drive pinion back and forth 2 to 3
times to check for unusual noise, rotation malfunction, and other malfunctions.
11. Check companion flange runout.
12. Install the differential case 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 the side gears and side gear thrust washers into the differential case.

CAUTION:
Make sure that the circular clip is installed to side gears.
3. Install the pinion mate thrust washers to the two pinion mate gears. Then install the pinion mate gears with the pinion mate thrust washers by aligning them in diagonally opposite positions and rotating them into the differential case.





4. Align the lock pin hole on the differential case with the lock pin hole on the pinion mate shaft, and install the pinion mate shaft.
5. Measure the side gear end play. If necessary, select the appropriate side gear thrust washers. Inspection and Adjustment.





6. Drive a new lock pin into the pinion mate shaft until it is flush with the differential case using suitable tool.

CAUTION:
Do not reuse lock pin.





7. Align the matching mark of the differential case with the mark of the drive gear, then place the drive gear onto the differential case.





8. Apply thread locking sealant into the threaded holes of the drive gear and install the bolts.
- Use Genuine Medium Strength Thread Locking Sealant or equivalent. Fluid Type Specifications.

CAUTION:
Make sure the drive gear back and threaded holes are clean.





9. Tighten the drive gear bolts to the specified torque. After tightening the drive gear bolts to the specified torque, tighten an additional 34� using Tool.

Tool number : KV10112100-A (BT-8653-A)


CAUTION:
- Always use Tool. Avoid tightening based on visual check alone.
- Tighten drive gear bolts in a crisscross pattern.





10. Press the side bearing inner races into the differential case using Tools.

Tool number
A: KV38100200 (J-26233)
B: ST33081000 ( - )


CAUTION:
Do not reuse side bearing inner race.





11. Install the differential case assembly with the side bearing outer races into the gear carrier.
12. Measure the side bearing preload torque. If necessary, select the appropriate side bearing adjusting washers. Inspection and Adjustment.





13. Insert the selected left and right side bearing adjusting washers in place between the side bearings and gear carrier.





14. Install the side bearing caps with the matching marks aligned and tighten the side bearing cap bolts to the specified torque.
15. Check and adjust the drive gear runout, tooth contact, drive gear to drive pinion backlash, and total preload torque.
Recheck the above items.
16. Install the side flanges.





17. Apply a 3.2mm (0.126 in) bead of sealant to the mating surface of the carrier cover.
- Use Genuine Silicone RTV or equivalent. Fluid Type Specifications.

CAUTION:
Remove any old sealant adhering to the mating surfaces.
Also remove any moisture, oil, or foreign material adhering to the application and mating surfaces.
18. Install the carrier cover to the gear carrier. Tighten the bolts to the specified torque. Service and Repair.
19. Install the side flange. Side Oil Seal.

Side Flange





1. Apply multi-purpose grease to the lips of the new side oil seal.
Then drive the new side oil seal in evenly until it becomes flush with the gear carrier using Tool.

Tool number : KV38100200 (J-26233)


CAUTION:
- Do not reuse side oil seal.
- Do not incline the new side oil seal when installing.
- Apply multi-purpose grease to the lips of the new side oil seal.





2. Install the side flange using Tool.
a. Install the Tool to the side oil seal as shown.

Tool number : KV38107900 (J-39352)

b. Insert the side flange until the serrated part of the side flange has engaged the serrated part of the side gear and remove the
Tool.
c. Drive in the side flange using suitable tool.

NOTE:
Installation is completed when the driving sound of the side flange turns into a sound which seems to affect the whole rear final drive assembly.