Assembly

Exploded View FFD-15:

ASSEMBLY
Drive Pinion Assembly





1. Install drive pinion rear bearing outer race and drive pinion front bearing outer race using Tools.
Tool number
A: ST30611000 (J-25742-1)
B: ST30613000 (J-25742-3)
C: KV38100200 (J-26233)

CAUTION:
^ First tap the drive pinion bearing outer race until it becomes flush with the gear carrier.
^ Do not reuse drive pinion front and rear bearing outer race.

2. Select drive pinion height adjusting washer.





3. Install the selected drive pinion height adjusting washer to the drive pinion. Press the drive pinion rear bearing inner race to it using Tool.
Tool number: ST30901000 (J-26010-01)

CAUTION:
^ Install the drive pinion height adjusting washer in the proper direction as shown.
^ Do not reuse drive pinion rear bearing inner race.





4. Install the collapsible spacer to the drive pinion.

CAUTION: Do not reuse collapsible spacer.

5. Apply differential gear oil to the drive pinion rear bearing, and install the drive pinion assembly to the gear carrier.
6. Apply differential gear oil to the drive pinion front bearing, and install the drive pinion front bearing inner race to the drive pinion assembly.

CAUTION: Do not reuse drive pinion front bearing inner race.





7. Press the drive pinion front bearing inner race to the drive pinion as far as drive pinion lock nut can be tightened using Tool.
Tool number: ST33200000 (J-26082)





8. Apply multi-purpose grease to the lips and differential gear oil to the circumference of the new front oil seal. Then drive the new front oil seal in evenly until it becomes flush with the gear carrier using Tools.
Tool number
A: ST30720000 (J-25405)
B: ST27863000 ( - )

CAUTION:
^ Do not reuse front oil seal.
^ Do not incline the new front oil seal when installing.
^ Apply multi-purpose grease to the lips and differential gear oil to the circumference of the new front oil seal.

9. Install the companion flange to the drive pinion while aligning the matching marks.





10. Apply anti-corrosive oil to the threads of the drive pinion and the seating surface of the new drive pinion lock nut. Then adjust the drive pinion lock nut tightening torque using Tool A, and check the drive pinion bearing preload torque using Tool B.
Tool number
A: KV38108300 (J-44195)
B: ST3127S000 (J-25765-A)
Drive pinion bearing preload torque: 1.08 - 1.66 Nm (0.11 - 0.16 kg-m, 10 - 14 in-lb)

CAUTION:
^ Do not reuse drive pinion lock nut.
^ Apply anti-corrosive oil to the threads of the drive pinion and the seating surface of the new drive pinion lock nut.
^ Adjust the drive pinion lock nut tightening torque to the lower limit first. Do not exceed the drive pinion lock nut specified torque. Refer to Exploded View FFD-15.
^ If the drive pinion bearing preload torque exceeds the specified value, replace collapsible spacer and tighten it again to adjust. Do not loosen drive pinion lock nut to adjust the drive pinion bearing preload torque.
^ After adjustment, rotate drive pinion back and forth 2 to 3 times to check for unusual noise, rotation malfunction, and other malfunctions.

11. Check companion flange runout. Refer to FFD-18, "Companion Flange Runout". Companion Flange Runout
12. Install the differential case assembly.

Differential Assembly





1. Install side gear thrust washers with the same thickness as the ones installed prior to disassembly, or reinstall the old ones on the side gears.





2. Install the side gears and side gear thrust washers into the differential case.
3. Install the pinion mate thrust washers to the two pinion mate gears. Then install the pinion mate gears with the pinion mate thrust washers by aligning them in diagonally opposite positions and rotating them into the differential case.





4. Install the pinion mate shaft and align the lock pin hole on the pinion mate shaft with the lock pin hole on the differential case.
5. Measure the side gear end play. If necessary, select the appropriate side gear thrust washers.





6. Drive a new lock pin into the pinion mate shaft until it is flush with the differential case using suitable tool.

CAUTION: Do not reuse lock pin.





7. Align the matching mark of the differential case with the mark of the drive gear, then place the drive gear onto the differential case.





8. Apply thread locking sealant into the threaded holes of the drive gear and install the new drive gear bolts.
^ Use Genuine High Strength Thread Locking Sealant or equivalent. Refer to GI-47, "Recommended Chemical Products and Sealants". Testing and Inspection

CAUTION: Make sure the drive gear back and threaded holes are clean.





9. Tighten the new drive gear bolts to the specified torque. Refer to Exploded View FFD-15. After tightening the new drive gear bolts to the specified torque, tighten an additional 34° to 39° using Tool.
Tool number: KV10112100-A (BT-8653-A)

CAUTION:
^ Always use Tool. Avoid tightening based on visual check alone.
^ Tighten new drive gear bolts in a crisscross pattern.





10. Press the new side bearing inner races to the differential case using Tools.
Tool number
A: ST33230000 (J-35867)
B: ST33061000 (J-8107-2)

CAUTION: Do not reuse side bearing inner races.

11. Install housing spacer into gear carrier.





12. Apply differential gear oil to the side bearings, and install the differential case assembly with the side bearing outer races into the gear carrier.

CAUTION: Do not reuse side bearing outer race when replacing side bearing inner race (replace as a set).





13. Insert left and right original side bearing adjusting washers in place between side bearings and gear carrier using Tool.
Tool number: KV38100600 (J-25267)





14. Install the side bearing caps with the matching marks aligned and tighten the side bearing cap bolts to the specified torque. Refer to Exploded View FFD-15.





15. Apply multi-purpose grease to the lips and differential gear oil to the circumference of the new side oil seal. Then drive the new side oil seal in evenly until it becomes flush with the gear carrier using Tools.
Tool number
A: ST30720000 (J-25405)
B: ST27863000 ( - )

CAUTION:
^ Do not reuse side oil seal.
^ Do not incline the new side oil seal when installing.
^ Apply multi-purpose grease to the lips and differential gear oil to the circumference of the new side oil seal.

16. Check and adjust tooth contact, backlash, drive gear runout and total preload torque.
Recheck above items.





17. Apply a 3 mm (0.12 in) bead of sealant to the mating surface of the carrier cover as shown.
^ Use Genuine Silicone RTV or equivalent. Refer to GI-47, "Recommended Chemical Products and Sealants". Testing and Inspection

CAUTION: Remove any old sealant adhering to the mating surfaces. Also remove any moisture, oil, or foreign material adhering to the application and mating surfaces.

18. Install the carrier cover to the gear carrier. Tighten the bolts to the specified torque. Refer to Exploded View FFD-15.

Differential side shaft





1. Press differential side shaft bearing to differential side shaft.

CAUTION: Do not reuse differential side shaft bearing.

2. Install snap ring (differential side shaft side).
3. Install differential side shaft assembly into gear carrier.
4. Install snap ring (hole side).





5. Apply multi-purpose grease to the lips and differential gear oil to the circumference of the new side oil seal. Then drive the new side oil seal in evenly until it becomes flush with the gear carrier using Tools.
Tool number
A: ST30720000 (J-25405)
B: ST27863000 ( - )

CAUTION:
^ Do not reuse side oil seal.
^ Do not incline the new side oil seal when installing.
^ Apply multi-purpose grease to the lips and differential gear oil to the circumference of the new side oil seal.