Step 2
ASSEMBLY-STEP 2
Assemble in the sequence shown in the image.
Bearing Inner Race (Differential gear)
1. Install the bearing inner race to the differential gear.
2. Install the bearing inner race to the differential gear.
Idle Gear
1. Install the retaining ring to the bearing.
2. Install the side cover (B) and bearing to the idle gear using a press.
3. Use a new lock nut, tighten it and crimp it.
Tightening torque: 127-206 N.m (13-21 m-kg, 94-152 ft-lb)
Adjustment of Pinion Height
1. Mount the transfer carrier on the SST.
2. Install the bearing outer race with the SST.
3. Install the bearing outer race using a brass drift
4. Install the spacer and bearing inner race to the SST.
NOTE: Use the spacer which was removed.
5. Install the drive pinion model to transfer carrier.
6. Install the bearing inner race, companion flange, washer, nut and the SST to the drive pinion model.
NOTE:
a. Use the nut which was removed.
b. Tighten the nut enough so that the drive pinion model can still be turned by hand.
7. Place the SST on the surface plate and set the dial indicator to "Zero".
8. Set the SST on top of the gauge block.
9. Place the measure probe of the dial indicator so that it contacts the area where the side bearing is installed in the carrier, and measure the lowest position. Measure both the left and the right sides.
10. Add the two (left and right) values obtained by the measurements taken in step 9, and then divide the total by 2.
Specification: 0 mm (0 in)
11. If it is not to the specification, adjust the pinion height by selection of a spacer.
NOTE: The spacer thicknesses are available in 0.03 mm (0.001 in) steps. Select the spacer thickness that is closest to that necessary.
12. Install the spacer to the drive pinion.
13. Press the bearing inner race on with the SST.
Adjustment of Drive Pinion Preload
1. Install the collapsible spacer.
2. Install the drive pinion assembly
3. Install the bearing inner race and companion flange and tighten the lock nut.
NOTE: Do not install the oil seal.
4. Turn the companion flange by hand to seat the bearing.
5. Measure the drive pinion preload.
Preload: 1-1.6 N.m (10-16 cm-kg, 8.7-13.9 in-lb)
6. If the specified preload can not be obtained, replace the collapsible spacer with a new one and check again.
7. Remove the nut, washer and companion flange.
8. Tap the oil seal into the differential carrier with the SST.
9. Coat companion flange with oil.
10. Install the companion flange and washer.
11. Install and tighten a new lock nut with the SST.
Tightening torque: 118-177 N.m (12-18 m-kg, 87-130 ft-lb)
Adjustment of Backlash
1. Position the idle gear assembly in the carrier.
2. Install the differential bearing caps making sure that the matching marks on the caps correspond with those on the carrier.
3. Loosely tighten the bearing cap bolts on each side and adjust the backlash.
4. Mark the ring gear at four points at approx. 90°C intervals on the ring gear and mount a dial indicator to the carrier so that the feeler comes in contact at a 90°C angle with one of the ring gear teeth.
5. Turn both adjustment screws equally until the backlash is within specifications with the SST.
Standard backlash: 0.09-0.11 mm (0.0035-0.0043 in)
4. After adjusting the backlash, tighten the adjustment screws equally until the distance between the pilot sections on the bearing caps becomes as specified distance.
Specification: 144.17-144.24 mm (5.6760-5.6787 in)
NOTE: When adjusting the differential bearing preload, care must be taken not to affect the backlash of the drive pinion gear and ring gear.
5. Tighten the bearing cap bolts to the specified torque.
Tightening torque:
A 37-52 N.m (3.8-5.3 m-kg, 27-38 ft-lb)
B 18-26 N.m (1.8-2.6 m-kg, 13-19 ft-lb)
6. Install the lock plates on the bearing caps to prevent the adjustment screws from loosening.
Inspection and Adjustment of Tooth Contact
1. Coat both surfaces of 6-8 teeth of the ring gear uniformly with a thin coating of red lead.
2. While moving the ring gear back and forth by hand, rotate the drive pinion several times and check the tooth contact.
3. If the tooth contact is correct, wipe off the red lead.
4. If it is not correct, adjust the pinion height, and then adjust the backlash.
1. Toe and flank contact
Replace the spacer with a thinner one, and move the drive pinion outward.
2. Heel and face contact
Replace the spacer with a thicker one, and bring the drive pinion closer in.