Part 3

REAR FINAL DRIVE ASSEMBLY


Disassembly and Assembly











6. Tighten side bearing caps to the specified torque installing Tools as shown.










7. Put scooter block on pinion height block. Make sure that dial indicator is level adjusting pressure with a hand. Dial indicator indicates "0".
8. Slide dial indicator along arbor. Record the maximum.





9. Adjust drive pinion height adjusting washer so that the maximum will be "0".

ASSEMBLY

Drive Pinion Assembly
1. Press a new drive pinion rear bearing outer race into gear carrier using Tools.











CAUTION:
Do not reuse drive pinion rear bearing.





2. Press a new drive pinion front bearing outer race into gear carrier using Tool.

Tool number : ST33022000 ( - )


CAUTION:
Do not reuse drive pinion front bearing.
3. Select drive pinion height adjusting washer. Refer to "Disassembly and Assembly".





4. Press a new drive pinion rear bearing inner race and drive pinion height adjusting washer to drive pinion using Tool.

Tool number : - (C - 4040)


CAUTION:
Do not reuse drive pinion rear bearing.
5. Apply gear oil to drive pinon rear bearing and drive pinon front bearing.
6. Install a new drive pinion front bearing inner race in gear carrier.
7. Install drive pinion front bearing thrust washer to gear carrier.





8. Apply multi-purpose grease to new front oil seal lip. Install new front oil seal into gear carrier using Tool.

Tool number : ST15310000 ( - )


CAUTION:
- Do not reuse front oil seal.
- Do not incline the new front oil seal when installing.
- Apply multi-purpose grease to the lip of the new front oil seal.





9. Install new collapsible spacer to drive pinion. And then install drive pinion assembly in gear carrier.

CAUTION:
- Do not reuse collapsible spacer.
- Do not damage front oil seal.





10. Install the companion flange onto the drive pinion while aligning the matching marks. Then tap the companion flange using suitable tool.

CAUTION:
Do not damage companion flange or front oil seal.
11. Apply anti-corrosive oil to the threads of the drive pinion and the seating surface of the new drive pinion lock nut and new drive pinion lock nut washer. Then adjust the drive pinion lock nut tightening torque using Tool A, and check the drive pinion bearing preload torque using Tool B.











CAUTION:
- Do not reuse drive pinion lock nut or drive pinion lock nut washer.
- 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 "Disassembly and Assembly".
- 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.

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





2. Assemble side gear and side gear thrust washer into differential case.
3. Align 2 pinion mate gears in diagonally opposite positions, then rotate and assemble them into differential case after assembling pinion mate thrust washer to pinion mate gear.





4. Align lock pin holes on differential case and shaft, and assemble pinion mate shaft.
5. Measure side gear end play. If necessary, select the appropriate side gear thrust washers. Refer to "Disassembly and Assembly".





6. Drive a new lock pin into pinion mate shaft, using Tool.

Tool number : ST23550000 ( - )







CAUTION:
Do not reuse lock pin.
7. Apply gear oil to gear tooth surfaces and thrust surfaces and check to see they turn properly.





8. Apply thread locking sealant to the back face of drive gear as shown.
- Use Genuine High Strength Thread Locking Sealant, Loctite 648 or equivalent. Refer to Fluid Type Specifications.






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





9. Align the matching mark of differential case with the mark of drive gear, then install drive gear.
10. Apply thread locking sealant into the threaded holes of the drive gear and install the bolts.





- Use Genuine High Strength Thread Locking Sealant, Loctite
648 or equivalent. Refer to Fluid Type Specifications.

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





11. Install new drive gear bolts, and then tighten to the specified torque. Refer to "Disassembly and Assembly".

CAUTION:
- Do not reuse the bolts.
- Tighten bolts in a crisscross fashion.





12. Press new side bearing inner races to differential case using Tools.






CAUTION:
Do not reuse side bearing.





13. Install side bearing adjusters into gear carrier.
14. Apply gear oil to side bearings. Install differential case assembly with side bearing outer races into gear carrier.





15. Align paint matching mark on side bearing caps with that on gear carrier and install side bearing caps on gear carrier.

CAUTION:
Do not tighten at this point. This allows further tightening of side bearing adjusters.





16. Tighten each side bearing adjusters using Tool.

Tool number : - (C - 4164)





17. Adjusting backlash of drive gear and drive pinion. Refer to "Disassembly and Assembly".
18. Check total preload. Refer to "Disassembly and Assembly".
19. Check tooth contact. Refer to "Disassembly and Assembly".





20. Apply a bead of sealant to the mating surface of the carrier cover as shown.
- Use Genuine Silicone RTV or equivalent. Refer to Fluid Type Specifications.

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.
21. Install the carrier cover to the gear carrier. Tighten the bolts to the specified torque. Refer to "Disassembly and Assembly".