Installation of Drive Pinion Assembly

INSTALLATION OF DRIVE PINION ASSEMBLY





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





2. Select drive pinion height adjusting washer. Refer to Specifications.
3. Install drive pinion adjusting washer in drive pinion, and press-fit pinion 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 A: ST30720000 (J25405)
Tool number B: KV38102510 (-)





6. Install drive pinion bearing spacer, pinion bearing adjusting shim and drive pinion in gear carrier.





7. Install ABS sensor unit and sensor rotor (2WD models).
ABS sensor unit bolt: 8 - 11 Nm (0.8 - 1.1 kg-m, 5.8 - 8.0 ft. lbs.)
8. Insert companion flange onto drive pinion. Tap the companion flange with a soft hammer until fully seated





9. Tighten pinion nut until total preload is within specification.
^ The threaded portion of drive pinion and pinion nut should be free from oil or grease.

Tool number: KV38108300 (J-44195)
Pinion nut: 127 - 294 Nm (13.0 - 30.0 kg-m, 94 - 217 ft. lbs.)
Pinion preload: 1.2 - 2.2 Nm (12 -22 kg-m, 10 - 19 inch lbs.)





10. Turn drive pinion in both directions several times, and measure pinion bearing preload using Tool.
Tool number: ST3127S000 (J25765-A)
Pinion bearing preload (With front oil seal): 1.4 - 1.7 Nm (14 - 17 kg-cm, 12 - 15 inch lbs.)
Pinion bearing preload (Without front oil seal): 1.2 - 1.5 Nm (12 - 15 kg-cm, 10 - 13 inch lbs.)
If preload is out of specification, adjust the thickness of spacer and shim combination by replacing shim and spacer with thinner one.
^ Start from the combination of thickest spacer and shim.
^ Combine each spacer and shim thickness one by one until the correct specification are achieved.
Drive pinion bearing preload adjusting spacer and shim: Refer to Specifications.