Part 2

FRONT FINAL DRIVE

Disassembly and Assembly

COMPONENTS

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.

- Drive pinion front bearing; make sure the J-34309-3 drive pinion front bearing seat is secured tightly against the J-34309-2 gauge anvil. Then turn the J-34309-7 drive pinion front bearing pilot to secure the drive pinon 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 J-34309-2 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 pinon bearings.

6. Measure the turning torque at the end of the J-34309-2 gauge anvil using Tool.

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. SEE Disassembly and Assembly, "Disassembly and Assembly".

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. Inspection And Adjustment.

13. Remove the Tool from the gear carrier and disassemble to retrieve the drive pinion bearings.

ASSEMBLY

Drive Pinion Assembly

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

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. 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.

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.

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.

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 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. SEE Disassembly and Assembly, "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.
11. Check companion flange runout. Inspection And Adjustment.
12. Install the differential case assembly. SEE Disassembly and 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. General Specification Inspection And Adjustment, "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 new drive gear bolts.
- Use Genuine High Strength Thread Locking Sealant or equivalent. Recommended Chemical Products And Sealants, "Recommended Chemical Products and
Sealants".
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
SEE Disassembly and Assembly. After tightening the new drive gear bolts to the specified torque, tighten an additional 34� to 39� using Tool (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.

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.

14. Install the side bearing caps with the matching marks aligned and tighten the side bearing cap bolts to the specified torque.
SEE Disassembly and Assembly.

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.

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. General Specification Inspection And Adjustment, "Inspection and Adjustment".
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. Recommended Chemical Products And Sealants.

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. SEE Disassembly and Assembly.

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.