Assemble
TOOLS REQUIRED^ J-24252 Installer
^ J-8092 Grip
^ J-21777-42 Pilot
^ J-23597-9 Nut and Bolt
^ J-23597-7 Gauge Plate
^ J-8001 Dial Indicator
^ J-23597-8 Disc (2 pcs)
^ J-6133-01 Installer
^ J-24250 Installer
^ J-8614-01 Pinion Flange Holder
^ J-39209 Punch
^ J-24244 Installer
^ J-8107-2 Pilot
^ J-22888 Remover
^ Or Equivalent
1. Diff. carrier.(21)
2. Outer bearing outer race.(20)
- Installer: J-24256.
- Grip: J-8092.
3. Inner bearing outer race.(17)
- Installer: J-24252.
- Grip: J-8092.
4. Adjust shim.(15) Adjustment of drive pinion mounting distance:
a. Apply gear oil to the inner and outer drive pinion bearing. Clean the pinion setting gauge set. Then install the gauge set together with the inner and outer bearings. Tighten the stud nut to 2.3 Nm (2.0 ft. lbs.).
(1) Pilot: J-21777-42
(2) Nut and bolt: J-23597-9
(3) Gauge plate: J-23597-7
b. Clean the side bearing bores. Install the dial indicator with the discs and arbor. Install and tighten the bearing cups to 98.1 Nm (72.3 ft lbs).
(1) Dial indicator: J-8001
(2) Disc (2 pcs.): J-23597-8
(3) Arbor: J-23597-1
(4) Gauge plate: J-23597-7
c. Set the dial indicator to "0". Place it on the mounting post of the gauging arbor with the contact button touching the indicator pad. Force the dial indicator downward until the needle has made a half turn clockwise. Tighten down the dial indicator in this position.
d. Position the plunger on the gauge plate. Move the gauging arbor slowly back and forth and locate the position at which the dial indicator shows the greatest deflection. At this point, once again set the dial indicator to "O". Repeat the procedure to verify the "O" setting.
e. After the ZERO setting is obtained, rotate the gauging arbor until the dial indicator rod does not touch the gauging plate. Record the number the dial indicator needle points to.
f. Record the pinion depth code on the head of the drive pinion. The number indicates a necessary change in the pinion mounting distance. A plus number indicates the need for a greater mounting distance (which can be achieved by decreasing the shim thickness). A minus number indicates the need for a smaller mounting distance (which can be achieved by increasing the shim thickness). If examination reveals pinion depth code "O", the pinion is "nominal".
g. Select the shim using the chart.
NOTE: When ordering shims, find the part number in the parts catalog by using the thickness of shims listed in the above table.
5. Inner bearing.(14) Place the shim on the drive pinion, with the chamfered side turned towards the pinion head then install the inner bearing onto the pinion using an installer and a press.
- Installer: J-6133-01
NOTE: Do not apply pressure to the roller cage. Apply pressure only to the inner race.
6. Collapsible spacer.(16) Discard the used collapsible spacer and install a new one.
7. Pinion gear.(13)
8. Outer bearing.(19)
9. Oil seal.(18) Use oil seal installer to install a new oil seal that has been soaked in rear axle lubricant.
- Installer: J-24250.
NOTE: Take care to use a front differential oil seal, NOT the rear differential oil seal.
10. Dust cover.(12)
11. Flange.(11)
12. Flange nut.(10)
a. Apply lubricant to the pinion threads.
b. Tighten the nut to the specified torque using the pinion flange holder.
- Pinion flange holder: J-8614-01.
^ Torque 177-275 Nm (130-203 ft. lbs.).
NOTE: Discard used flange nut and install new one. Do not overtighten the flange nut.
c. Pinion bearing preload
- Measure the bearing preload by using a torque meter. Note the scale reading required to rotate the flange.
- Continue tightening until the specified starting torque is obtained. Starting torque New bearing 0.88 Nm (7.8 inch lbs). Used bearing 0.44 Nm (3.9 inch lbs).
- Using special tool, caulk the flange nut at two points.
- Punch: J-39209.
NOTE: When caulking, be sure to turn the nut to insure that there is no change in bearing preload. Make sure of preload again as instructed in step c. above.
13. Adjust shim:(9)
a. Attach the side bearing to the differential assembly without shims. Support the opposite side using a pilot to prevent bearing damage.
(1) Installer: J-24244
(2) Drive handle: J-8092
(3) Pilot: J-8107-2
b. Insert the differential cage assembly with bearing outer races into the side bearing bores of the carrier.
c. Using two sets of feeler gauges, insert a feeler stock of sufficient thickness between each bearing outer race and the carrier to remove all end play. Make certain the feeler stock is pushed to the bottom of the bearing bores. Mount the dial indicator on the carrier so that the indicator stem is at right angles to a tooth on the ring gear.
- Dial indicator: J-8001.
d. Adjust feeler gauge thickness from side to side until ring gear backlash is in the specified range. Backlash 0.155 mm (0.006 inch). With zero end play and correct backlash established, remove the feeler gauge packs, determine the thickness of the shims required and add 0.05 mm (0.002 inch) to each shim pack to provide side bearing preload. Always use new shims.
e. Remove side bearing.
- Remover: J-22888
- Pilot: J-8107-2.
14. Side bearing.(8) Install the side bearings together with the selected shims.
(1) Installer: J-24244
(2) Drive handle: J-8092
(3) Pilot: J-8107-2
15. Side bearing outer race.(7)
16. Diff. cage assembly.(6)
17. Bearing cup.(5) Align the setting marks applied at disassembly.
18. Bolt.(4)
- Tighten the bolt to the specified torque.
^ Torque 98.1 Nm (72.3 ft. lbs.).
- Measure the amount of run-out of the ring gear at its rear face.
^ Standard 0.02 mm (0.001 inch).
^ Limit 0.05 mm (0.002 inch).
19. Gear Tooth Contact Pattern Check and Adjustment. Apply a thin coat of Prussian blue or equivalent to the faces of the 7 - 8 teeth of the ring gear. Check the impression of contact on the ring gear teeth and make necessary adjustment as described if the contact is abnormal.
20. Axle case.(3)
21. Differential assembly.(2)
a. Clean the faces of the front axle case and differential carrier. Apply the recommended liquid gasket or its equivalent to the sealing side of the axle case and the carrier.
b. Attach the differential case and the carrier assembly to the front axle case and tighten the nuts and bolts. The axle case bolt is used for drainage.
^ Torque 25.5 Nm (18.8 ft. lbs.).
c. Install the axle shaft assemblies.
d. Fill the axle case with hypoid gear lubricant, to just below the filler hole.
^ Lubricant capacity 1.4 lit. (1.48 qt.).
23. Bolt.(1)