Part 1
DISASSEMBLYPRE-INSPECTION
Before disassembling final drive, perform the following inspection.
- Total preload
1) Turn drive pinion in both directions several times to set bearing rollers.
2) Check total preload with Tool.
Tool number: ST3127SO00 (J25765-A)
Total preload: 1.4 - 3.1 Nm (14 - 32 kg-cm, 12 - 28 inch lbs.)
- Ring gear to drive pinion backlash
Check ring gear-to-drive pinion backlash with a dial indicator at several points.
Ring gear-to-drive pinion backlash: 0.10 - 0.15 mm (0.0039 - 0.0059 inch)
- Ring gear runout
Check runout of ring gear with a dial indicator.
Runout limit: 0.05 mm (0.0020 inch)
- Tooth contact
Check tooth contact.
DIFFERENTIAL CARRIER
1. Using two 45 mm (1.77 inch) spacers, mount carrier on Tool.
Tool number: KV38100800 (J25604-01)
2. For proper reinstallation, paint or punch matchmarks on one side of the side bearing cap.
Bearing caps are line-board during manufacture. Replace them in their proper positions.
3. Remove side bearing caps.
4. Lift differential case assembly out with Tool.
Tool number: HT72400000( - )
Keep the side bearing outer races together with inner cone do not mix them up.
Also, keep side bearing spacer and adjusting shims together with bearings.
5. Loosen drive pinion nut and pull off companion flange.
6. Take out drive pinion (together with rear bearing inner race, bearing spacer and adjusting washer).
7. Remove oil seal.
8. Remove front bearing inner race.
9. Remove side oil seal.
10. Remove pinion bearing outer races with a brass drift.
11. Remove pinion rear bearing inner race and drive pinion height adjusting washer with suitable tool.
DIFFERENTIAL CASE
1. Remove side bearing inner cones.
To prevent damage to bearing, engage puller jaws in groove.
Tool number:
(A) ST33051001 (J22888-20)
(B) ST33061000 (J8107-2)
Be careful not to confuse left- and right-hand parts. Keep bearing and bearing race for each side together.
2. Loosen ring gear bolts in a criss-cross fashion.
3. Tap ring gear off the differential case with a soft hammer.
Tap evenly all around to keep ring gear from binding.
R200V ONLY
4. Loosen screws on differential cases A and B.
5. Separate differential cases A and B.
R200 ONLY
4. Drive out pinion mate shaft lock pin, with punch from ring gear side.
INSPECTION
RING GEAR AND DRIVE PINION
Check gear teeth for scoring, cracking or chipping. If any part is damaged, replace ring gear and drive pinion as a set (hypoid gear set).
BEARING
1. Thoroughly clean bearing.
2. Check bearings for wear, scratches, pitting or flaking.
Check tapered roller bearing for smooth rotation. If damaged, replace outer race and inner cone as a set.
DIFFERENTIAL CASE ASSEMBLY
Check mating surfaces of differential case, side gears, pinion mate gears, pinion mate shaft and thrust washers.
R200V ONLY
In addition, check viscous coupling for oil leakage. If necessary, replace it with new one.
ADJUSTMENT
For quiet and reliable final drive operation, the following five adjustments must be made correctly.
1. Side bearing preload
2. Pinion gear height
3. Pinion bearing preload
4. Ring gear to pinion backlash.
5. Ring and pinion gear tooth contact pattern
SIDE BEARING PRELOAD
A selection of side bearing adjusting washers is required for successful completion of this procedure.
1. Make sure all parts are clean. Make sure, also, the bearings are well lubricated with light oil or DEXRON TMI1 type automatic transmission fluid.
2. Place the differential carrier, with side bearings and bearing races installed, into the final drive housing.
3. Insert left and right original side bearing adjusting washers in place between side bearings and carrier.
4. Using Tool, drive in side bearing spacer in place between side bearing adjusting washer in left side and carrier.
5. Install the side bearing caps in their correct locations and torque the bearing cap retaining bolts.
Specification: 88 - 98 Nm (9 - 10 kg-m, 65 - 72 ft. lbs.)
6. Turn the carrier several times to seat the bearings.
7. Measure the turning torque of the carrier at the ring gear retaining bolts with a spring gauge, J8129.
Specification: 34.3 - 39.2 N (3.5 - 4.0 kg, 7.7 - 8.8 lb.) of pulling force at the ring gear bolt
8. If the turning torque is not within the specifications correct the torque as follows:
- If the turning torque is less than the specified range, install washers of greater thickness.
- If the turning torque is greater than the specification, install thinner washers.
- See the SDS section for washer dimensions and part numbers.
9. Record the total amount of washer thickness required for the correct carrier side bearing preload.
10. Remove the carrier from the final drive housing. Save the selected preload washers for later use during the assembly of the final drive unit.
PINION GEAR HEIGHT AND PINION BEARING PRELOAD
1. Make sure all parts are clean and that the bearings are well lubricated.
2. Assemble the pinion gear bearings into the pinion preload shim selector Tool, J34309.
- Front pinion bearing - make sure the J34309-3 front pinion bearing seat is secured tightly against the J34309-2 gauge anvil. Then turn the front pinion bearing pilot, J34309-5, to secure the bearing in its proper position.
- Rear pinion bearing - the rear pinion bearing pilot, J34309-8, is used to center the rear pinion bearing only. The rear pinion bearing locking seat, J34309-4, is used to lock the bearing to the assembly.
R200V ONLY
- Installation of J34309-9 and J34309-16 - place a suitable 2.5 mm (0.098 inch) thick plain washer between J34309-9 and J34309-16 Both surfaces of J34309-9 and J34309-16 must be parallel with a clearance of 2.5 mm (0.098 inch).
3. Install the pinion rear bearing inner cone into the final drive housing. Then place the pinion preload shim selector Tool, J34309-1, gauge screw assembly.
4. Assemble the front pinion bearing inner cone and the J34309-2 gauge anvil. Assemble them together with the J34309-1 gauge screw in the final drive housing. Make sure that the pinion height gauge plate, J34309-16, will turn a full 360 degrees.
Tighten the two sections together by hand.
5. Turn the assembly several times to seat the bearings.
6. Measure the turning torque at the end of the J34309-2 gauge anvil using torque wrench J25765A.
Turning torque specification: 1.0 - 1.3 Nm (10 - 13 kg-cm, 8.7 - 11.3 inch lbs.)
7. Place the J34309-11 "R200A" pinion height adapter onto the gauge plate and tighten it by hand.
CAUTION: Make sure all machined surfaces are clean.
PINION BEARING PRELOAD WASHER SELECTION
8. Place the solid pinion bearing spacer, small end first, over the J34309-2 gauge anvil. Seat the small end squarely against the tip of the J34309-1 gauge screw in the tool recessed portion.
9. Select the correct thickness of pinion bearing preload adjusting washer. Select by using a standard gauge of 3.5 mm (0.138 inch) and your J34309-101 feeler gauge. The exact measure you get with your gauges is the thickness of the adjusting washer required. Select the correct washer from the following chart.
Drive pinion bearing preload adjusting washer: Refer to image.
10. Set aside the selected correct pinion bearing preload adjusting washer. Use it when assembling the pinion gear and bearings into the final drive.