Pre-Inspection (Checking Gear Measurements)

ASSEMBLY INSPECTION AND ADJUSTMENT
Total Preload Torque





1. Turn drive pinion in both directions several times to set bearing rollers.
2. Check total preload using preload gauge set.
Tool number: ST3127S000 (J-25765-A)
Total preload (with oil seal) 2.38 - 5.16 Nm (0.25 - 0.52 kg-m, 21 - 45 inch lbs.)

NOTE: Total preload torque = Pinion bearing torque + Side bearing torque

^ If measured value is out of the specification, disassemble it to check and adjust each part. Adjust the pinion bearing preload and the side bearing preload.
Adjust the pinion bearing preload first, then adjust the side bearing preload.
When the preload torque is large
On pinion bearings: Replace collapsible spacer.
On side bearings: Loosen side bearing adjuster.
When the preload is small
On pinion bearings: Tighten drive pinion nut.
On side bearings: Tighten side bearing adjuster.

Tooth Contact
Checking gear tooth contact pattern is necessary to verify correct relationship between drive gear and drive pinion. Gears which are not positioned in proper arrangement may be noisy and/or have a short life. Check gear tooth contact pattern to obtain the best contact for low noise and long life.

1. Remove rear cover. Refer to DISASSEMBLY.





2. Thoroughly clean drive gear and drive pinion teeth.
3. Apply red lead to drive gear.

CAUTION: Apply red lead to both the faces of 3 to 4 gears at 4 locations evenly spaced on drive gear.








4. Hold companion flange steady by hand and rotate drive gear in both directions.
5. If outside the standard, adjust drive pinion height adjusting washer and backlash. Refer to Drive Pinion Height Adjusting Washer, Backlash.

Backlash





1. Remove rear cover Refer to DISASSEMBLY.
2. Check drive gear to drive pinion backlash using a dial indicator at several points.
Drive gear to drive pinion backlash: 0.08 - 0.13 mm (0.0031 - 0.0051 inch)
3. If outside the standard, adjust side bearing adjuster.

CAUTION: Check tooth contact and total preload after adjusting side bearing adjuster. Refer to Total Preload Torque, Tooth Contact.

a. Remove adjuster lock plate.
b. Loosen side bearing cap bolts.





c. Tighten or loosen each side bearing adjusters using Tool.
Tool number: - (C - 4164)





d. In case of lots of backlash, loosen side bearing adjuster A and tighten side bearing adjuster B. In case of less backlash, loosen side bearing adjuster B and tighten side bearing adjuster A.





e. After adjusting backlash and tighten cap bolts to the specified torque. Refer to Components.
f. Install adjuster lock plate and tighten to the specified torque. Refer to Components.

CAUTION: Install adjuster lock plate to grooving of differential lock solenoid.

Companion Flange Runout





1. Fit a dial indicator onto companion flange face (inner side of propeller shaft mounting bolt holes).
2. Rotate companion flange to check for runout.
Runout limit: 0.10 mm (0.0039 inch) or less
3. Fit a test indicator to the inner side of companion flange (socket diameter).
4. Rotate companion flange to check for runout.
Runout limit: 0.13 mm (0.0051 inch) or less
5. If the runout value is outside the repair limit, follow the procedure below to adjust.
a. Check for runout while changing the phase between companion flange and drive pinion by 90° step, and search for the point where the runout is the minimum.
b. If the runout value is still outside of the limit after the phase has been changed, replace companion flange.
c. If the runout value still outside of the limit after companion flange has been replaced, check drive pinion bearing and drive pinion assembly.