Assembly

DRIVE PINION

Assembly

1.Select drive pinion adjusting shim. Refer to "Adjustment" Adjustment.
2.Install selected drive pinion adjusting shim to drive pinion.





3.Install inner race of drive pinion bearing (front side) to drive pinion with a drift (A) [SST: ST23860000 (-)].

CAUTION:
- Never reuse drive pinion bearing (front side).
- Apply gear oil to the drive pinion bearing (front side).
4.Assemble the inner race of drive pinion bearing (rear side) into the transfer case.

CAUTION:
- Never reuse drive pinion bearing (rear side).
- Apply gear oil to the drive pinion bearing (rear side).





5.Install drive pinion oil seal to transfer case with drifts so that it becomes flush with case end surface.






CAUTION:
- Never reuse oil seal.
- Apply multi-purpose grease onto oil seal lips, and gear oil onto the circumference.
6.Assemble a collapsible spacer onto the drive pinion.

CAUTION:
Never reuse the collapsible spacer.





7.Assemble drive pinion assembly into the transfer case, and then install companion flange (1) to drive pinion.
NOTE:
Align matching marks (A) on the thread edge of companion flange and drive pinion and install companion flange if drive pinion is reused.





8.Tap the companion flange with a plastic hammer as far as the lock nut can be tightened.

CAUTION:
Never damage drive pinion oil seal.
9.Apply anti-corrosive oil to the thread and seat of the lock nut, and temporarily tighten lock nut to the drive pinion.

CAUTION:
Never reuse lock nut.





10.Tighten lock nut within the specified torque range with a preload gauge (A) [SST: ST3127S000 (-)] so that the drive pinion bearing preload is within standard.

Standard
Drive pinion bearing preload: Refer to "Preload Torque" Preload Torque.

CAUTION:
- Start the tightening of lock nut from lower limit of the specified torque. Check the preload every 5� to 10� while tightening the lock nut.
- Replace the collapsible spacer and tighten it again to adjust if preload exceeds the specified value. Never loosen lock nut to adjust preload.
- After adjustment, rotate the drive pinion back and forth from 2 to 3 times to check for unusual noise, sticking, binding, and so on.
11.Install ring gear shaft assembly. Refer to "Assembly" Assembly.
12.Install adapter case. Refer to "Assembly" Assembly.
13.Check backlash, tooth contact, total preload and companion flange runout. Refer to "Adjustment" Adjustment.

CAUTION:
Measure the total preload without the adapter case oil seal.