Overhaul

REAR FINAL DRIVE

Disassembly and Assembly

COMPONENTS

ASSEMBLY INSPECTION AND ADJUSTMENT
- Drain the differential gear oil before inspection and adjustment. Changing Differential Gear Oil Checking Differential Gear Oil.
- Remove and install the carrier cover as necessary for inspection and adjustment. Service and Repair.

Total Preload Torque
1. Remove the side flanges if necessary. Side Oil Seal.

CAUTION:
The side flanges must removed in order to measure total preload torque.
2. Rotate the drive pinion back and forth 2 to 3 times to check for unusual noise and rotation malfunction.
3. Rotate the drive pinion at least 20 times to check for smooth operation of the bearings.

4. Measure the 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.

CAUTION:
Select a side bearing adjusting washer for right and left individually.

Drive Gear Runout

1. Fit a dial indicator to the drive gear back face.
2. Rotate the drive gear to measure runout.

Runout limit : 0.05 mm (0.0020 in) or less

- If the runout is outside of the limit, check the condition of the drive gear assembly. Foreign material may be caught between the drive gear and differential case, or the differential case or drive gear may be deformed.

CAUTION:
Replace drive gear and drive pinion as a set.

Tooth Contact

1. Apply red lead to the drive gear.

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

2. Rotate the drive gear back and forth several times. Then check for correct drive pinion to drive gear tooth contact as shown.

CAUTION:
Check tooth contact on drive side and reverse side.

3. If the tooth contact is improperly adjusted, follow the procedure below to adjust the pinion height (dimension X).

- If the tooth contact is near the face (face contact), or near the heel
(heel contact), use a thicker drive pinion height adjusting washers to move the drive pinion closer to the drive gear. Inspection And Adjustment.

- If the tooth contact is near the flank (flank contact), or near the toe
(toe contact), use a thinner drive pinion height adjusting washers to move the drive pinion farther from the drive gear. Inspection And Adjustment.

Backlash

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

Backlash : 0.13 - 0.18 mm (0.0051 - 0.0070 in)

- If the backlash is outside of the specification, change the thickness of the side bearing adjusting washers.

CAUTION:
Do not change the total thickness of side bearing adjusting washers as it will change the side bearing preload torque.

Companion Flange Runout

1. Rotate companion flange and check for runout on the outer face of the companion flange using suitable tool.

Runout limit : 0.08 mm (0.0031 in) or less

2. If the runout is outside of 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

Side Flange
1. Drain the differential gear oil if necessary.

2. Remove the side flange using Tools.

3. Remove the side oil seal using suitable tool.

CAUTION:
Do not to damage gear carrier.

Differential Assembly
1. Remove the side flanges.
2. Remove the carrier cover bolts.

3. Remove the carrier cover bolts and separate the carrier cover from the gear carrier 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.

4. Mount the carrier on the Tool using two 45 mm (1.77 in) spacers.

Tool number : KV38100800 (J-25604-01)

5. For proper reinstallation, paint matching marks on one side of the side bearing cap and gear carrier.

CAUTION:
- For matching marks, use paint. Do not damage side bearing cap or gear carrier.
- Side bearing caps are line-board during manufacture. The matching marks are used to reinstall them in their original positions.

6. Remove the side bearing caps.

7. Lift the differential case assembly out using Tool.

Tool number : HT72400000 ( - )

CAUTION:

- Keep side bearing outer races together with inner race.
Do not mix them up.
- Keep side bearing adjusting washers together with side bearings.

8. Remove the side bearing inner races using Tools.

CAUTION:
- Engage Tool jaws in bearing groove to prevent damage.
- Place copper plates between the side bearing and drive gear and the vise to prevent damage.
- Do not remove side bearing inner race unless it is being replaced.

9. For proper reinstallation, paint matching marks on the differential case and drive gear.

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

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

12. Remove the lock pin of the pinion mate shaft from the drive gear side using suitable tool.

13. Remove the pinion mate shaft.

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

Drive Pinion Assembly
1. Remove the differential assembly.

2. Remove the drive pinion lock nut using suitable tool.
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.

4. Remove the companion flange using suitable tool.

5. Press the drive pinion assembly (with rear inner bearing race and collapsible spacer) out of the gear carrier.

CAUTION:
Do not drop drive pinion assembly.
6. Remove the front oil seal.

CAUTION:
Do not damage gear carrier.
7. Remove the drive pinion front bearing inner race.

8. Remove the drive pinion rear bearing inner race and drive pinion height adjusting washer using Tool.

Tool number: : ST30031000 (J-22912-01)

9. Remove the drive pinion front and rear bearing outer races by tapping them uniformly using suitable tool.

CAUTION:
Do not damage gear carrier.

INSPECTION AFTER DISASSEMBLY
Clean the disassembled parts. Then inspect the parts for wear or damage. If wear or damage are found, follow the measures below.

Drive Pinion and Drive Gear
- If the drive pinion and drive gear teeth do not mesh or line-up correctly, determine the cause and adjust, repair, or replace as necessary.
- If the drive pinion or drive gear are worn, cracked, damaged, pitted or chipped (by friction) noticeably, replace with new drive pinion and drive gear.
- Drive pinion and drive gear are supplied in matched sets only. Matching numbers on both drive pinion and drive gear are etched for verification. If a new drive pinion and drive gear set are being used, verify the numbers of each drive pinion and drive gear before proceeding with assembly.

Bearing
- If bearings are chipped (by friction), pitted, worn, rusted, scratched, or unusual noise is coming from bearing, replace with new bearing assembly (as a new set).
- Bearing must be replaced with a new one whenever disassembled.

Side Gear and Pinion Mate Gear
- If any cracks or damage are found on the surface of the teeth, replace with new one.
- If any worn or chipped marks are found on the side of the side gear and pinion mate gear which contact the thrust washer, replace with new one.
- Replace both side gear and pinion mate gear as a set when replacing side gear or pinion mate gear.

Side Gear Thrust Washer and Pinion Mate Thrust Washer
- If any chips (by friction), damage, or unusual wear are found, replace with new one.

Gear Carrier
- If any wear or cracks are found on the contact sides of gear carrier, replace with new one.

Companion Flange
- If any chips (about 0.1mm, 0.004 in) or other damage on the companion flange surface which contacts the front oil seal lips are found, replace with new one.

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: 0.20 mm (0.0079 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. Inspection And Adjustment.

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.

Side Bearing Preload Torque
- A selection of side bearing adjusting washers is required for successful completion of this procedure.

1. 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).

2. Insert the left and right original side bearing adjusting washers in place between side bearings and gear carrier.

3. Align the matching mark on the side bearing cap with the matching mark on the gear carrier.
4. Install the side bearing caps and tighten the side bearing cap bolts to the specified torque.
5. Turn the differential assembly several times to seat the side bearings.

6. To determine side bearing preload torque, measure the pulling force of the differential assembly at the drive gear bolt using Tool.

NOTE:
If pulling force of the differential assembly at the drive gear bolt is within specification, side bearing preload torque will also be within specification. Inspection And Adjustment.

7. If the pulling force is outside the specification, use a thicker or thinner side bearing adjusting washer to adjust. Inspection And Adjustment.

CAUTION:
Select a side bearing adjusting washer for right and left individually.
8. Record the total amount of washer thickness required for the correct side bearing preload torque.

ASSEMBLY

Drive Pinion Assembly

1. Install the drive pinion front and rear bearing outer races using
Tools.

CAUTION:
Do not reuse drive pinion front and rear bearing outer race.
2. Select a drive pinion height adjusting washer. Inspection And Adjustment.

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 : ST30022000 ( - )

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

4. Assemble 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 suitable spacer.

8. Apply multi-purpose grease to the lips of the new front oil seal.
Then drive the new front oil seal in evenly until it becomes flush with the 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 lips 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 suitable tool (A), and check the drive pinion bearing preload torque using Tool (B).

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.
- 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.
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.

CAUTION:
Make sure that the circular clip is installed to side gears.
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. Align the lock pin hole on the differential case with the lock pin hole on the pinion mate shaft, and install the pinion mate shaft.
5. Measure the side gear end play. If necessary, select the appropriate side gear thrust washers. Inspection And Adjustment.

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 bolts.
- Use Genuine Medium Strength Thread Locking Sealant or equivalent. Fluid Type Specifications.

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

9. Tighten the drive gear bolts to the specified torque. After tightening the drive gear bolts to the specified torque, tighten an additional 34� using Tool.

Tool number : KV10112100-A (BT-8653-A)

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

10. Press the side bearing inner races into the differential case using Tools.

CAUTION:
Do not reuse side bearing inner race.

11. Install the differential case assembly with the side bearing outer races into the gear carrier.
12. Measure the side bearing preload torque. If necessary, select the appropriate side bearing adjusting washers.

13. Insert the selected left and right side bearing adjusting washers in place between the side bearings and gear carrier.

14. Install the side bearing caps with the matching marks aligned and tighten the side bearing cap bolts to the specified torque.
15. Check and adjust the drive gear runout, tooth contact, drive gear to drive pinion backlash, and total preload torque.
Recheck the above items.
16. Install the side flanges.

17. Apply a 3.2mm (0.126 in) bead of sealant to the mating surface of the carrier cover.
- Use Genuine Silicone RTV or equivalent. 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.
18. Install the carrier cover to the gear carrier. Tighten the bolts to the specified torque. Service and Repair.
19. Install the side flange. Side Oil Seal.

Side Flange

1. Apply multi-purpose grease to the lips of the new side oil seal.
Then drive the new side oil seal in evenly until it becomes flush with the gear carrier using Tool.

Tool number : KV38100200 (J-26233)

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

2. Install the side flange using Tool.
a. Install the Tool to the side oil seal as shown.

Tool number : KV38107900 (J-39352)

b. Insert the side flange until the serrated part of the side flange has engaged the serrated part of the side gear and remove the
Tool.
c. Drive in the side flange using suitable tool.

NOTE:
Installation is completed when the driving sound of the side flange turns into a sound which seems to affect the whole rear final drive assembly.