Part 1

REAR FINAL DRIVE ASSEMBLY


Disassembly and Assembly


COMPONENTS






ASSEMBLY INSPECTION AND ADJUSTMENT
- Drain the differential gear oil before inspection and adjustment. Refer to Rear Final Drive M226.
- Remove and install the carrier cover as necessary for inspection and adjustment. Refer to Rear Final Drive M226.

Total Preload Torque
1. Rotate the drive pinion back and forth 2 to 3 times to check for unusual noise and rotation malfunction.
2. Rotate the drive pinion at least 20 times to check for smooth operation of the bearings.





3. Measure total preload torque using Tool.






NOTE:
Total preload torque = Drive pinion bearing preload torque + Side bearing preload torque
- If the measured value is out of the specification, check and adjust each part. Adjust the drive pinion bearing preload torque first, then adjust the side bearing preload torque.






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

NOTE:
Apply red lead to both faces of three to four gears, at four locations evenly spaced on the drive gear.





3. Hold companion flange steady by hand and rotate drive gear in both directions.





4. If outside the standard, adjust drive pinion height adjusting washer and backlash. Refer to "Disassembly and Assembly". and Inspection And Adjustment.

Backlash
1. Fit a dial indicator to the drive gear face to measure the backlash.






Backlash: 0.12 - 0.20 mm (0.0050 - 0.0079 in)

2. If the backlash is outside of the specification, adjust each side bearing side bearing adjuster.
a. Remove adjuster lock plate.
b. Loosen side bearing cap bolts.





c. Tighten or loosen each side bearing adjuster using Tool.

Tool number : - (C - 4164)












CAUTION:
Do not change the side bearing side bearing adjusters by different amounts as it will change the side bearing preload torque.





d. Tighten side bearing cap bolts to the specified torque. Refer to "Disassembly and Assembly".
e. Install adjuster lock plate and tighten to the specified torque. Refer to "Disassembly and Assembly".

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

Companion Flange Runout
1. Rotate companion flange and check for runout on the companion flange face (inner side of the bolt holes) and companion flange inner side (socket diameter) using suitable tool.











2. If the runout is outside the runout limit, follow the procedure below to adjust.
a. Rotate the companion flange on the drive pinion by 90�, 180�and 270� while checking for the position where the runout is minimum.
b. If the runout is still outside of the runout limit after the companion flange has been rotated on the drive pinion, possible cause could be an assembly malfunction of drive pinion and drive pinion bearing or a malfunctioning drive pinion bearing.
c. If the runout is still outside of the runout limit after repair of the assembly of drive pinion and drive pinion bearing or drive pinion bearing, replace the companion flange.

DISASSEMBLY

Differential Assembly
1. Remove carrier cover bolts.





2. Remove carrier cover using Tool.

Tool number : KV10111100 (J-37228)

CAUTION:
- Do not damage the mating surface.
- Do not insert flat-bladed screwdriver, this will damage the mating surface.





3. For proper reinstallation, paint matching mark on one side of side bearing cap.

CAUTION:
- Side bearing caps are line-board for initial assembly. The matching marks are used to reinstall them in their original positions.
- For matching mark, use paint. Do not damage side bearing cap.
4. Remove adjuster lock plates.





5. Remove side bearing caps.
6. Remove side bearing adjusters using Tool.






Tool number : - (C - 4164)

7. Keep side bearing outer races together with inner races. Do not mix them up. Also, keep side bearing adjusters together with bearing.





8. Remove side bearing adjusters from gear carrier.
9. Remove side bearing inner races using Tool.






Tool number : ST33081000 ( - )


CAUTION:
Do not damage differential case.





10. For proper reinstallation, paint matching mark on differential case and drive gear.

CAUTION:
Use paint for matching marks. Do not damage differential case or drive gear.
11. Remove drive gear bolts.
12. Tap the drive gear off the differential case using suitable tool.

CAUTION:
Tap evenly all around to keep drive gear from binding.





13. Remove the lock pin of the pinion mate shaft from the drive gear side using Tool.

Tool number : ST23550000 ( - )






14. Remove pinion mate shaft.
15. Turn the pinion mate gear, then remove the pinion mate gear, pinion mate thrust washer, side gear and side gear thrust washer from differential case.






Drive Pinion Assembly
1. Remove differential case assembly. Refer to "Disassembly and Assembly".
2. Remove drive pinion lock nut and washer using Tool.






Tool number : KV40104000 ( - )

3. Put matching marks on the companion flange and drive pinion using paint.

CAUTION:
Use paint to make the matching marks. Do not damage the companion flange or drive pinion.