Adjusting and Selecting Washers
Exploded View FFD-15:
ADJUSTING AND SELECTING WASHERS
Side Gear Back Clearance
^ Assemble the differential parts if they are disassembled.
1. Place the differential case straight up so that the side gear to be measured is upward.
2. Using feeler gauges, measure the clearance between the side gear back and differential case at three different points, while rotating the side gear. Average the three readings to calculate the clearance. (Measure the clearance of the other side as well.)
Side gear back clearance: 0.1 mm (0.004 in) or less.
^ If the side gear back clearance is outside of the specification, use a thicker or thinner side gear thrust washer to adjust. Refer to FFD-35, "Side Gear Thrust Washer". Side Gear Thrust Washer
If the side gear back clearance is greater than specification:
Use a thicker side gear thrust washer.
If the side gear back clearance is less than specification:
Use a thinner side gear thrust washer.
CAUTION:
^ Insert feeler gauges with the same thickness on both sides to prevent side gear from tilting.
^ Each gear should rotate smoothly without excessive resistance during differential motion.
^ Select a side gear thrust washer for right and left individually.
NOTE: Side gear back clearance is clearance between side gear and differential case for adjusting side gear backlash.
Drive Pinion Height
1. Make sure all parts are clean and that the bearings are well lubricated.
2. Assemble the drive pinion bearings onto the Tool.
Tool number: - (J-34309)
^ Drive pinion front bearing; make sure the J-34309-3 drive pinion front bearing seat is secured tightly against the J34309-2 gauge anvil. Then turn the J-34309-7 drive pinion front bearing pilot to secure the drive pinion front bearing in its proper position.
^ Drive pinion rear bearing; the J-34309-8 drive pinion rear bearing pilot is used to center the drive pinion rear bearing only. The J-34309-4 drive pinion rear bearing locking seat is used to lock the drive pinion rear bearing to the assembly.
^ Installation of J-34309-9 and J-34309-16; place a suitable 2.5 mm (0.098 in) thick plain washer between J-34309-9 and J-34309-16. Both surfaces of J-34309-9 and J-34309-16 must be parallel with a clearance of 2.5 mm (0.098 in).
3. Install the drive pinion rear bearing inner race into the gear carrier. Then insert the drive pinion height adjusting washer selector tool, J-34309-1, gauge screw assembly.
4. Assemble the drive pinion front bearing inner race and the J34309-2 gauge anvil. Assemble them together with the J-34309-1 gauge screw in the gear carrier. Make sure that the drive pinion height gauge plate, J-34309-16, will turn a full 360°. Tighten the two sections together by hand.
5. Turn the assembly several times to seat the drive pinion bearings.
6. Measure the turning torque at the end of the J-34309-2 gauge anvil using Tool.
Tool number: ST3127S000 (J-25765-A)
Turning torque specification: 1.0 - 1.6 Nm (0.11 - 0.16 kg-m, 9 - 14 in-lb)
7. Place the J-34309-10 "R180A" drive pinion height adapter onto the gauge plate and tighten it by hand.
CAUTION: Make sure all machined surfaces are clean.
8. Position the side bearing discs, Tool, and arbor firmly into the side bearing bores. Install the side bearing caps and tighten the side bearing cap bolts to the specified torque. Refer to Exploded View FFD-15.
Tool number: - (J-25269-18)
9. Select the correct standard drive pinion height adjusting washer thickness. Select by using a standard gauge of 3 mm (0.12 in) and your J-34309-101 feeler gauge. Measure the distance between the J-34309-10 drive pinion height adapter, including the standard gauge and the arbor.
10. Write down the exact measurement (the value of feeler gauge).
11. Correct the drive pinion height adjusting washer size by referring to the drive pinion "head number".
There are two numbers painted on the drive pinion. The first one refers to the drive pinion and drive gear as a matched set. This number should be the same as the number on the drive gear. The second number is the drive pinion "head number". It refers to the ideal drive pinion height from standard for quietest operation. Use the following chart to determine the correct drive pinion height adjusting washer.
12. Select the correct drive pinion height adjusting washer. Refer to FFD-35, "Drive Pinion Height Adjusting Washer". Drive Pinion Height Adjusting Washer
13. Remove the Tool from the gear carrier and disassemble to retrieve the drive pinion bearings.
Tool number: - (J-34309)