Part 2

PINION HEIGHT ADJUSTING WASHER SELECTION





11. Now, position the side bearing discs, J25269-4, and arbor firmly into the side bearing bores.
Install the side bearing caps and tighten the cap bolts to proper torque.





12. Select the correct standard pinion height adjusting washer thickness. Select by using a standard gauge of 3 mm (0.12 inch) and your J34309-101 feeler gauge. Measure the distance between the J34309-11 pinion height adapter including the standard gauge and the arbor.





13. Write down your exact measurement (the value of feeler gauge).





14. Correct the pinion height washer size by referring to the "pinion head number".
There are two numbers painted on the pinion gear. The first one refers to the pinion and ring gear as a matched set. This number should be the same as the number on the ring gear. The second number is the "pinion head height number". It refers to the ideal pinion height from standard for quietest operation. Use the following chart to determine the correct pinion height washer.





15. Select the correct pinion height washer from the following chart.





Drive pinion height adjusting washer: Refer to image.





16. Remove the J34309 pinion preload shim selector Tool from the final drive housing. Then disassemble to retrieve the pinion bearings.

TOOTH CONTACT
Checking gear tooth contact pattern is necessary to verify correct relationship between ring gear and drive pinion.
Hypoid gears which are not positioned in proper arrangement may be noisy and/or have a short life. Check gear tooth contact pattern to obtain the best contact for low noise and long life.





1. Thoroughly clean ring gear and drive pinion teeth.
2. Lightly apply a mixture of powdered titanium oxide and oil or the equivalent. Apply it to 3 or 4 teeth of ring gear drive side.








3. Hold companion flange steady by hand and rotate the ring gear in both directions.

DIFFERENTIAL CASE
Whenever side gears or pinion mate gears are replaced, selection of thrust washers should be carried out.
Before selecting thrust washers, make sure all parts are clean and well lubricated with hypoid gear oil.

THRUST WASHER SELECTION
R200V ONLY
1. Install the previously removed thrust washer on right side gear. On left side gear, install a suitable thrust washer. Temporarily tighten differential cases using two screws.





2. Position differential assembly so that right side gear is on the upper side. Place two feeler gauges of 0.03 mm (0.0012 inch) thickness between right side gear and thrust washer as shown.
Do not insert feeler gauge in oil groove portion of differential case.
3. Rotate right side gear with a suitable tool attached to splines. If hard to rotate, replace thrust washer on left side gear with a thinner one.
4. Replace both 0.03 mm (0.0012 inch) feeler gauges with 0.10 mm (0.0039 inch) gauges. At this point, make sure right side gear does not rotate. If it rotates, replace thrust washer on left side gear with a thicker one to prevent rotation.

R200 ONLY





1. Install side gears, pinion mate gears, thrust washers and thrust block into differential case.





2. Fit pinion mate shaft to differential case so that it meets lock pin holes.


















3. Adjust clearance between rear face of side gear and thrust washer by selecting side gear thrust washer. Refer to image.

Clearance between side gear thrust washer and differential case: 0.15 mm (0.0059 inch) or less

ASSEMBLY





1. Install differential case A and B. -R200V ONLY-





1. Install pinion mate shaft lock pin with a punch. -R200 ONLY-
Make sure lock pin is flush with case.





2. Place differential case on ring gear.
3. Apply locking sealant to ring gear bolts, and install them.
Tighten bolts in a criss-cross fashion, lightly tapping bolt head with a hammer.





4. Press-fit side bearing inner cones on differential case with Tool.
Tool number:
(A) KV38100300 (J25523)
(B) ST33061000 (J8107-2)

DIFFERENTIAL CARRIER





1. Press-fit front and rear bearing outer races with Tools.
Tool number:
(A) ST30611000 (J25742-1)
(B) ST30621000 (J25742-2)
(C) ST30613000 (J25742-3)

2. Select pinion bearing adjusting washer and drive pinion bearing spacer.





3. Install selected drive pinion height adjusting washer in drive pinion. Using press and Tool, press-fit pinion rear bearing inner cone into it.

Tool number: ST30901000 (J26010-01)





4. Place pinion front bearing inner cone in final drive housing.









5. Set drive pinion assembly (as shown in figure at left) in differential carrier and install drive pinion, with press and suitable tool.
Stop when drive pinion touches bearing.
Apply multi-purpose grease to pinion rear bearing inner race, pinion front bearing inner race.





6. Apply multi-purpose grease to cavity at sealing lips of oil seal. Install front oil seal with Tool.
Tool number: KV38100500 ( - )





7. Install companion flange, and tighten pinion nut to specified torque with suitable tool.
Make sure that threaded portion of drive pinion and pinion nut are free from oil or grease.





8. Turn drive pinion in both directions several times, and measure pinion bearing preload.

Pinion bearing preload: 1.1 - 1.4 Nm (11 - 14 kg-cm, 9.5 - 12.2 inch lbs.)

When pinion bearing preload is outside specifications, replacement is required for pinion bearing adjusting washer and spacer. Replace with those of different thickness.





9. Install differential case assembly with side bearing outer races into gear carrier.





10. Insert original left and right side bearing adjusting washers in place between side bearings and carrier.





11. Using Tool, drive in side bearing spacer in place between side bearing adjusting washer in left side and carrier.
Tool number: KV38100600(J25267)





12. Align mark on bearing cap with that on gear carrier and install bearing cap on gear carrier.





13. Check runout of ring gear with a dial indicator.

Runout limit: 0.05 mm (0.0020 inch)





14. Measure ring gear to drive pinion backlash with a dial indicator.

Ring gear to drive pinion backlash: 0.10 - 0.15 mm (0.0039 - 0.0059 inch)

- If backlash is too small, adjustment of shim thickness is required. Decrease thickness of left shim and increase thickness of right shim by the same amount.
If backlash is too great, reverse the above procedure.
Never change the total amount of shims as it will change the bearing preload.





15. Check total preload with Tool.
When checking preload, turn drive pinion in both directions several times to seat bearing rollers correctly.

Total preload: 1.4 - 3.1 Nm (14 - 32 kg-cm, 12 - 28 inch lbs.)

- If preload is too great, remove the same amount of shim from each side.
- If preload is too small, add the same amount of shim to each side.

Never add or remove a different number of shims for each side. Difference in number of shims will change ring gear to drive pinion backlash.

16. Recheck ring gear to drive pinion backlash. Increase or decrease in thickness of shims will cause change to ring gear to pinion backlash.
- Check whether the backlash varies excessively in different places. Foreign matter may be caught between the ring gear and the differential case causing the trouble.
- The backlash can vary greatly even when the ring gear runout is within a specified range. In that case, replace the hypoid gear set or differential case.
17. Check tooth contact.





18. Apply multi-l5urpose grease to cavity at sealing lips of oil seal. Install side oil seal.
Tool number: KV38100200(J26233)
19. Install rear cover and gasket.