Assembly

DRIVE PINION

Assembly






1.Install a drive pinion adjusting shim of the same thickness as was installed prior to disassembly. Press pinion rear bearing outer race into gear carrier, using the drift [SST: ST1713000
( - ).

CAUTION:
- At first, using a hammer, tap bearing outer race until it becomes flush to gear carrier.
- Never reuse pinion rear bearing outer race.





2.Press pinion front bearing outer race into gear carrier, using the drift [SST: 33230000 (J-25805-01)].

CAUTION:
- At first, using a hammer, tap bearing outer race until it becomes flush to gear carrier.
- Never reuse pinion front bearing outer race.





3.Press pinion rear bearing inner race to drive pinion, using the drift [SST: ST23860000 (-)].

CAUTION:
Never reuse pinion rear bearing inner race.
4.After checking and adjusting the tooth contact and backlash of the drive gear and drive pinion following the procedure below.
a.Apply gear oil to the pinion rear bearing, and assemble the drive pinion to the gear carrier.

CAUTION:
Never assemble a collapsible spacer.





b.Apply gear oil to pinion front bearing, and assemble pinion front bearing inner race to drive pinion. Using the drifts and stand, press pinion front bearing inner race to drive pinion as far as drive pinion nut can be tightened.






CAUTION:
Never reuse pinion front bearing inner race.
c.Temporarily tighten removed drive pinion nut to drive pinion.
NOTE:
Use removed drive pinion nut only for the preload measurement.





d.Fit the drive pinion socket (A) [SST: KV38109500 (-)]
onto the drive pinion spline. Using the pinion nut wrench (B)
[SST: KV38109400 (-)], tighten drive pinion nut to the specified preload torque.





Standard
Pinion bearing preload: Refer to "Preload Torque" Rear Final Drive R145.

CAUTION:
Drive pinion nut is tightened with no collapsible spacer.
Never overtighten it. While measuring the preload, tighten it by 5� to 10�.





e.Apply gear oil to side bearings, and install new side bearing adjusting shims with the same thickness or re-install the old ones to the same mounting position they were in prior to disassembly. Set the drifts [SST: KV40100610 (J-26089)] to the right and left. Install differential case assembly to gear carrier.

CAUTION:
- The drifts shall be placed on the center of the adjusting shims.
- The pressure shall be as low as possible to install gear carrier assembly to differential assembly. The maximum pressure shall be 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
- If adjusting shims are installed by tapping, gear carrier may be damaged. Avoid tapping.
f.Check and adjust the tooth contact. Refer to "Adjustment" Adjustment.
g.Check and adjust the backlash. Refer to "Adjustment" Adjustment.
h.Remove dummy cover set, and remove differential case assembly.





i.Remove drive pinion nut and press drive pinion assembly out of gear carrier.

CAUTION:
Never drop drive pinion assembly.
j.Remove pinion front bearing inner race.





5.Assemble collapsible spacer to drive pinion.

CAUTION:
- Be careful of the mounting direction of collapsible spacer.
- Never reuse collapsible spacer.





6.Apply gear oil to pinion front bearing, and assemble pinion front bearing inner race to drive pinion. Using the drifts and stand, press pinion front bearing inner race to drive pinion as far as drive pinion nut can be tightened.






CAUTION:
Never reuse pinion front bearing inner race.
7.Apply anti-corrosive oil to the thread and seat of drive pinion nut, and temporarily tighten drive pinion nut to drive pinion.

CAUTION:
Never reuse drive pinion nut.





8.Fit the drive pinion socket (A) [SST: KV38109500 (-)]
onto the drive pinion spline. Using the pinion nut wrench (B)
[SST: KV38109400 (-)], adjust the drive pinion nut tightening torque and pinion bearing preload torque.





Drive pinion tightening torque:.

Standard
Pinion bearing preload: Refer to "Preload Torque" Rear Final Drive R145.

CAUTION:
- Adjust the lower limit of the drive pinion nut tightening torque first.
- If the preload torque exceeds the specified value, replace collapsible spacer and tighten it again to adjust. Never loosen drive pinion nut to adjust the preload torque.
- After adjustment, rotate drive pinion back and forth 2 to 3
times to check for unusual noise, rotation malfunction, and other malfunctions.
9.Install differential case assembly. Refer to "Assembly" Assembly.

CAUTION:
Never install rear cover.
10.Install dummy cover set [SST: KV381086S1 (-)], and check drive gear runout, tooth contact, and backlash. Refer to "Adjustment" Adjustment.
11.Remove dummy cover set [SST: KV381086S1 (-)], then install rear cover, and side oil seal.
Refer to "Assembly" Assembly.
12.Check total preload torque. Refer to "Adjustment" Adjustment.
13.Install electric controlled coupling assembly. Refer to "Assembly" Assembly.
14.Check companion flange runout. Refer to "Adjustment" Adjustment.