Reassembly
REASSEMBLY
LUBRICATION, SEALING AND ADHESIVE POINTS
REASSEMBLY SERVICE POINTS
]]A[[ OIL SEAL INSTALLATION
Use special tools MB990938, MB990934 to insert the oil seal, and then apply a thin coat of multipurpose grease to the lip of the oil seal.
]]B[[ DRIVE PINION FRONT BEARING OUTER RACE INSTALLATION
Use special tools MB990938, MB990936 to press-fit the drive pinion front bearing outer races into the gear carrier.
]]C[[ DRIVE PINION REAR BEARING OUTER RACE INSTALLATION
Use special tools MB990938, MB990934 to press-fit the drive pinion rear bearing outer races into the gear carrier.
]]D[[ PINION HEIGHT ADJUSTMENT
Adjust the drive pinion height as follows:
1. Apply multipurpose grease to the washer of special tool MB990819.
2. Install special tool MB990819, drive pinion front and rear bearing inner races to the gear carrier.
3. Tighten the nut of special tool MB990819 while measuring the turning torque of the drive pinion. Gradually keep tightening the nut of special tool MB990819 until the turning torque of the drive pinion (without oil seal) is at the standard value.
Standard Value:
4. Clean the side bearing hub.
5. Install special tool MB991170 to the side bearing hub of the gear carrier, and then install the bearing cap.
NOTE: Always check that the notch is in the shown position and that special tools MB991170 are touching firmly against the side bearing hub.
6. Use a feeler gauge to measure the clearance (A) between special tools MB9911170, MB990819.
7. Remove special tools MB991170, MB9908119.
8. Use a micrometer to measure special tools MB9911170, MB990819 in the places (13, C) shown in the illustration.
9. Install the bearing cap, and then use a cylinder gauge and micrometer to measure the inside diameter (D) of the bearing cap as shown in the illustration.
10. Calculate the thickness (E) of the required drive pinion front shim by the following formula, and then select a shim which most closely matches this thickness. E = A + B + C- 1/2D - 100.0 mm (3.94 inches)
11. Fit the selected drive pinion front shim(s) to the drive pinion and press-fit the drive pinion front bearing inner race by using special tool MB990802.
]]E[[ DRIVE PINION TURNING TORQUE ADJUSTMENT
Adjust the drive pinion turning torque by using the following procedure:
1. Insert the drive pinion into the gear carrier, and then install the drive pinion spacer, the drive pinion rear shim, the drive pinion rear bearing inner race, and the companion flange in that order.
NOTE: Do not install the oil seal.
2. Tighten the companion flange to the specified torque by using special tool MB990767.
3. Measure the drive pinion turning torque (without the oil seal).
Standard Value:
4. If the drive pinion turning torque is not within the range of the standard value, adjust the preload by replacing the drive pinion rear shim(s) or the drive pinion spacer.
5. Remove the companion flange and drive pinion again. Then, after inserting the drive pinion rear bearing inner race into the gear carrier, use special tools MB990031 or MB990699 press-fit the oil seal.
6. Install the drive pinion assembly and companion flange with mating marks properly aligned, and tighten the companion flange self-locking nut to the specified torque by using special tool MB990767.
7. Measure the drive pinion turning torque (with the oil seal).
Standard Value:
8. If the drive pinion turning torque is not within the standard value, check the tightening torque of the companion flange self-locking nut and the oil seal.
]]F[[ DIFFERENTIAL GEAR BACKLASH ADJUSTMENT
1. Assemble the side gears, side gear spacers, pinion gears and pinion washers into the differential case.
2. Temporarily install the pinion shaft.
NOTE: Do not drive in the lock pin yet.
3. Insert a wedge between the side gear and the pinion shaft to lock the side gear.
4. Measure the differential gear backlash with a dial indicator on the pinion gear.
Standard value: 0 - 0.076 mm (0 - 0.0030 Inch)
Limit: 0.2 mm (0.08 inch)
5. If the differential gear backlash exceeds the limit, adjust the backlash by installing thicker side gear spacers.
6. If adjustment is not possible, replace the side gears and pinion gears as a set.
7. Measure the differential gear backlash once again, and confirm that it is within the limit.
]]G[[ LOCK PIN INSTALLATION
1. Align the pinion shaft lock pin hole with the differential case lock pin hole, and drive in the lock pin.
2. Stake the lock pin with a punch at two points.
]]H[[ DRIVE GEAR INSTALLATION
1. Clean the drive gear attaching bolts.
2. Remove the adhesive adhered to the threaded holes of the drive gear by turning the special tool (tap M 10 x 1.25), and then clean the threaded holes by applying compressed air.
3. Apply the 3M[TM] AAD Part number 8730 or AAD Part number 8731 or equivalent to the threaded holes of the drive gear.
4. Install the drive gear onto the differential case with the mating marks properly aligned. Tighten the bolts to the specified torque in a diagonal sequence.
Tightening torque: 78 - 88 Nm (58 - 65 ft. lbs.)
]]I[[ SIDE BEARING INNER RACE INSTALLATION
Use special tool MB990802 to press-fit the side bearing inner races into the differential case.
]]J[[ DRIVE GEAR BACKLASH ADJUSTMENT
Adjust the drive gear backlash by the following procedures:
1. Install the side bearing spacers, which are thinner than those removed, to the side bearing outer races, and then mount the differential case assembly into the gear carrier.
NOTE: Select side bearing spacers with the same thickness for both the drive pinion side and the drive gear side.
2. Push the differential case assembly to one side, and measure the clearance between the gear carrier and the side bearing adjusting spacer with a feeler gauge.
3. Measure the thickness of the side bearing adjusting spacers on one side, select two pairs of spacers which correspond to that thickness plus one half of the clearance plus 0.05 mm (0.002 inch), and then install one pair each to the drive pinion side and the drive gear side.
4. Install the side bearing adjusting spacers and differential case assembly, as shown in the illustration, to the gear carrier.
5. Tap the side bearing adjusting spacers with special tool MB990939 to fit them to the side bearing outer race.
6. Align the mating marks on the gear carrier and the bearing cap, and then tighten the bearing cap.
7. With the drive pinion locked in place, measure the drive gear backlash with a dial indicator on the drive gear.
NOTE: Measure at four points or more on the circumference of the drive gear.
Standard value: 0.11 - 0.16 mm (0.004 - 0.006 Inch)
8. Change the side bearing adjusting spacers as illustrated, and then adjust the drive gear backlash between the drive gear and the drive pinion.
NOTE: When increasing the number of side bearing adjusting spacers, use the same number for each, and as few as possible.
9. Check the drive gear and drive pinion for tooth contact. If poor contact is evident, make adjustment.
10. Measure the drive gear runout at the shoulder on the reverse side of the drive gear.
Limit: 0.05 mm (0.002 inch)
11. If the drive gear runout exceeds the limit, reinstall by changing the phase of the drive gear and differential case, and remeasure.
12. If adjustment is not possible, replace the differential case or replace the drive gear and drive pinion as a set.