Part 2

Pinion Gear Height





1. Make sure all parts are clean and that the bearings are well lubricated.
2. Assemble the pinion gear bearings into the differential shim selector tool.
Tool number: - (J-34309)





^ Pinion front bearing; make sure the J-34309-3 pinion front bearing seat is secured tightly against the J-34309-2 gauge anvil. Then turn the pinion front bearing pilot, J-34309-5, to secure the bearing in its proper position.
^ Pinion rear bearing; the pinion rear bearing pilot, J-34309-8, is used to center the pinion rear bearing only. The pinion rear bearing locking seat, J-34309-4, is used to lock the bearing to the assembly.
^ Installation of J-34309-9 and J-34309-16; place a suitable 2.5 mm (0.098 inch) 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 inch).





3. Install the pinion rear bearing inner race into gear carrier. Then place the pinion preload shim selector tool, J-34309-1, gauge screw assembly.





4. Assemble the pinion front bearing inner race and the J-34309-2 gauge anvil. Assemble them together with the J-34309-1 gauge screw in gear carrier. Make sure that the pinion height gauge plate, J-34309-16, 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 J-34309-2 gauge anvil using preload gauge.
Tool number: ST3127SOOO (J-25765-A)
Turning torque specification: 1.0 - 1.3 Nm (0.11 - 0.13 kg-m, 9 - 11 inch lbs.)





7. Place the J-34309-11 "R200A" 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, J-25269-4, and arbor firmly into the side bearing bores. Install the bearing caps and tighten bearing cap mounting bolts to the specified torque.





9. Select the correct standard pinion height adjusting washer thickness. Select by using a standard gauge of 3 mm (0.12 inch) and your J-34309-101 feeler gauge. Measure the distance between the J-34309-11 pinion height adapter including the standard gauge and the arbor.





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





11. Correct the pinion height washer size by referring to the "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 "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.





12. Select the correct pinion height adjusting washer.





13. Remove the J-34309 differential shim selector tool from the final drive housing. Then disassemble to retrieve the pinion bearings.

ASSEMBLY
Drive Pinion Assembly





1. Install front and rear bearing outer races using drifts.
Tool number A: ST30720000 (J-25405)
B: KV40105230 (-)
C: ST30611000 (J-25742-1)
D: ST30613000 (J-25742-3)

CAUTION:
^ At first, using a hammer, tap bearing outer race until it becomes flat to gear carrier.
^ Do not reuse pinion front and rear bearing outer race.

2. Select drive pinion height adjusting washer.






3. Install selected drive pinion height adjusting washer to drive pinion. Press pinion rear bearing inner race to it, using drift.
Tool number: ST30901000 (J-26010-01)

CAUTION:
^ Pay attention to the direction of pinion height adjusting washer. (Assemble as shown in the figure.)
^ Do not reuse pinion rear bearing inner race.





4. Assemble collapsible spacer to drive pinion.

CAUTION: Do not reuse collapsible spacer.

5. Apply gear oil to pinion rear bearing, and assemble drive pinion into gear carrier.
6. Apply gear oil to pinion front bearing, and assemble pinion front bearing inner race to drive pinion assembly.

CAUTION: Do not reuse pinion front bearing inner race.





7. Using suitable spacer, press the pinion front bearing inner race to drive pinion as far as drive pinion nut can be tightened.





8. Using the drift, install front oil seal as shown in figure.
Tool number: ST30720000 (J-25405)

CAUTION:
^ Do not reuse oil seal.
^ When installing, do not incline oil seal.
^ Apply multi-purpose grease onto oil seal lips, and gear oil onto the circumference of oil seal.





9. Install companion flange.

NOTE: When reusing drive pinion, align the matching mark of drive pinion with the matching mark A of companion flange, then install companion flange.





10. Apply gear oil to the thread and seat of drive pinion lock nut, and temporarily tighten drive pinion lock nut to drive pinion.

CAUTION: Do not reuse drive pinion lock nut.

11. Adjust to the drive pinion lock nut tightening torque and pinion bearing preload torque.
Tool number A: KV40104000 (-)
B: ST3127S000 (J-25765-A)
Drive pinion lock nut tightening torque: 147 - 323 Nm (15 - 32 kg-m, 109 - 238 ft. lbs.)
Drive pinion bearing preload: 2.65 - 3.23 Nm (0.27 - 0.32 kg-m, 24 - 28 inch lbs.)

CAUTION:
^ Adjust to the lower limit of the drive pinion lock nut tightening torque first.
^ If the 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 preload torque.
^ After adjustment. rotate drive minion back and forth 2 to 3, times to check for unusual noise, rotation malfunction, and other malfunctions.

12. Install differential case assembly.

CAUTION: Do not install rear cover yet.

13. Check and adjust drive gear runout, tooth contact, drive gear to drive pinion backlash, and companion flange runout. Recheck above items. Readjust the above description, if necessary.
14. Check total preload torque.
15. Install rear cover.

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 side gears and thrust washers into differential case.

CAUTION: Make sure that the circular clip is installed to side gears.
3. Align 2 pinion mate gears in diagonally opposite positions, then rotate and install them into differential case after installing thrust washer to pinion mate gear.





4. Align the lock pin holes on differential case with shaft, and install pinion mate shaft.
5. Measure side gear end play. If necessary, select the appropriate side gear thrust washers.





6. Drive a lock pin into pinion mate shaft, using a punch. Make sure lock pin is flush with differential case.

CAUTION: Do not reuse lock pin.





7. Align the matching mark of differential case with the mark of drive gear, then place drive gear.





8. Apply thread locking sealant into the thread hole of drive gear.
^ Use Genuine High Strength Thread Locking Sealant or equivalent.

CAUTION: Drive gear back and threaded holes shall be cleaned and degreased sufficiently.





9. Install drive gear on the mounting bolts, and then tighten to the specified torque.

CAUTION:
^ Tighten bolts in a crisscross fashion.
^ After tightening the bolt to the specified torque, tighten the bolts additionally by turning the bolts 31 to 36 degrees.





10. Press side bearing inner races to differential case, using the drift and the base.
Tool number A: KV38100300 (J-25523)
B: ST33061000 (J-8107-2)

CAUTION: Do not reuse side bearing inner race.





11. Install differential case assembly with side bearing outer races into gear carrier.
12. Measure side bearing preload. If necessary, select the appropriate side bearing adjusting washers.





13. Insert selected left and right side bearing adjusting washers in place between side bearings and gear carrier.





14. Align matching mark on bearing cap with that on gear carrier.
15. Install bearing caps and tighten bearing cap mounting bolts to the specified torque.





16. Using the drift, drive side oil seals until it becomes flush with the case end.
Tool number: KV38100200 (J-26233)

CAUTION:
^ Do not reuse oil seal.
^ When installing, do not incline oil seal.
^ Apply multi-purpose grease onto oil seal lips, and gear oil onto the circumference of oil seal.

17. Check and adjust drive gear runout, tooth contact, drive gear to drive pinion backlash, and total preload torque.
Recheck above items. Readjust the above description, if necessary.





18. Apply sealant to mating surface of rear cover.
^ Use Genuine Silicone RTV or equivalent.

CAUTION: Remove old sealant adhering to mounting surfaces. Also remove any moisture, oil, or foreign material adhering to application and mounting surfaces.

19. Install rear cover on gear carrier and tighten mounting bolts with the specified torque.
20. Install side flange with the following procedure.





a. Attach the protector to side oil seal.
Tool number: KV38107900 (J-39352)
b. After the side flange is inserted and the serrated part of side gear has engaged the serrated part of flange, remove the protector.





c. Put a suitable drift on the center of side flange, then drive it until sound changes.

NOTE: When installation is completed, driving sound of the side flange turns into a sound which seems to affect the whole final drive.

d. Confirm that the dimension of the side flange installation (Measurement A) in the figure comes into the following.
Measurement A: 326 - 328 mm (12.83 - 12.91 inch)