Differential Carrier

DIFFERENTIAL CARRIER





1. Press-fit front and rear bearing outer races with Tools.
Tool numbers:
A ST30611000 (J25742-1)
B ST30621000 (J25742-5)
C ST30613000 (J25742-3)





2. Select pinion height adjusting washer. Refer to "ADJUSTMENT". Adjustment
3. Install pinion height adjusting washer in drive pinion, and press-fit rear bearing inner cone in it, with press and Tool.
Tool number: ST30901000 (J26010-01)





4. Place pinion front bearing inner cone in gear carrier.





5. Apply multi-purpose grease to cavity at sealing lips of oil seal. Install front oil seal.
Tool number: KV38100500 (J25273)





6. Place drive pinion bearing spacer, drive pinion bearing adjusting washer and drive pinion in gear carrier.





7. Insert companion flange into drive pinion by tapping the companion flange with a soft hammer.





8. Tighten pinion nut to 127 Nm (13 kg-m, 94 ft. lbs.).
The threaded portion of drive pinion and pinion nut should be free from oil or grease.
Tool number: KV38108300 (J44195)





9. Tighten the pinion nut by very small degrees until the specified preload is achieved. When checking the preload, turn the drive pinion in both directions several times to set the bearing rollers.
Tool number: ST3127SOOO (J25765-A)
Pinion bearing preload: 1.1 - 1.7 Nm (11 - 17 kg-cm, 9.5 - 14.8 inch lbs.)
This procedure will have to be repeated if:
^ Maximum preload is achieved before the minimum pinion nut torque is reached.
^ Minimum preload is not achieved before maximum pinion nut torque is reached.





10. Select side bearing adjusting washer. Refer to Adjustment. Adjustment
11. Install differential case assembly with side bearing outer races into gear carrier.





12. Insert left and right side bearing adjusting washers in place between side bearing and carrier.





13. Drive in side bearing spacer with Tool.
Tool number: KV38100600 (J25267)





14. Align mark on bearing cap with that on gear carrier and install bearing cap on gear carrier.





15. Measure ring gear-to-drive pinion backlash with a dial indicator.
Ring gear-to-drive pinion backlash: 0.13 - 0.18 mm (0.0051 - 0.0071 inch)
^ If backlash is too small, decrease thickness of right shim and increase thickness of left shim by the same amount. If backlash is too great, reverse the above procedure.
Never change the total amount of shims as it will change the bearing preload.





16. Check total preload with Tool. When checking preload, turn drive pinion in both directions several times to seat bearing rollers correctly.
Total preload: 1.2 - 2.3 Nm (12 - 23 kg-cm, 10 - 20 inch lbs.)
Tool number: ST3127S000 (J25765-A)





^ If preload is too great, remove the same amount of shim from each side.
^ If preload is too small, add the same amount of shim to each side.
Never add or remove a different number of shims for each side as it will change ring gear-to-drive pinion backlash.
17. Recheck ring gear-to-drive pinion backlash because increase or decrease in thickness of shims will cause change of ring gear-to-pinion backlash.





18. Check runout of ring gear with a dial indicator.
Runout limit: 0.05 mm (0.0020 inch)
^ If backlash varies excessively in different places, the variance may have resulted from foreign matter caught between the ring gear and the differential case.
^ If the backlash varies greatly when the runout of the ring gear is within a specified range, the hypoid gear set or differential case should be replaced.
19. Check tooth contact. Refer to "ADJUSTMENT". Adjustment
20. Install rear cover and gasket.