Part 1

Disassembly and Assembly (R200V LSD)





COMPONENTS

ASSEMBLY INSPECTION AND ADJUSTMENT
^ Before inspection and adjustment, drain gear oil.

Total Preload Torque
1. Secure final drive assembly onto an attachment.
Tool number: KV38100800 (J-25604-01)
2. Remove side flanges.
3. Rotate drive pinion back and forth 2 to 3 times to check for unusual noise and rotation malfunction.





4. Rotate drive pinion at least 20 times to check for smooth operation of the bearing.
5. Measure total preload with the preload gauge.
Tool number: ST3127S000 (J-25765-A)
Total preload torque (With oil seal): 2.84 - 3.75 Nm (0.29 - 0.38 kg-m, 26- 33 inch lbs.)

NOTE: Total preload torque = Pinion bearing torque + Side bearing torque.

^ If measured value is out of the specification, disassemble it to check and adjust each part. Adjust the pinion bearing preload and side bearing preload. Adjust the pinion bearing preload first, then adjust the side bearing preload.

When the preload torque is large
On pinion bearings: Replace the collapsible spacer.
On side bearings: Use thinner side bearing adjusting washers by the same amount to each side.

When the preload is small
On pinion bearings: Tighten the drive pinion nut.
On side bearings: Use thicker side bearing adjusting washers by the same amount to each side.

Drive Gear Runout
1. Remove rear cover.
2. Fit a dial indicator to the drive gear back face.





3. Rotate the drive gear to measure runout.
Runout limit: 0.05 mm (0.0020 inch) or less
^ If the runout is outside of the repair limit, check drive gear assembly condition; foreign material may be caught between drive gear and differential case, or differential case or drive gear may be deformed, etc.

CAUTION: Replace drive gear and drive pinion gear as a set.

Tooth Contact
1. Remove rear cover.





2. Apply red lead to drive gear.

CAUTION: Apply red lead to both the faces of 3 to 4 gears at 4 locations evenly spaced on drive gear.





3. Rotate drive gear back and forth several times, check drive pinion gear to drive gear tooth contact.

CAUTION: Check tooth contact on drive side and reverse side.









4. If tooth contact is improperly adjusted, follow the procedure below to adjust the pinion height (dimension X).





^ If the tooth contact is near the face (face contact), or near the heel (heel contact), thicken pinion height adjusting washers to move drive pinion closer to drive gear.





If the tooth contact is near the flank (flank contact), or near the toe (toe contact), thin pinion height adjusting washers to move drive pinion farther from drive gear.

Backlash
1. Remove rear cover.





2. Fit a dial indicator to the drive gear face to measure the backlash.
Backlash: 0.10 - 0.15 mm (0.0039 - 0.0059 inch)
If the backlash is outside of the specified value, change the thickness of side bearing adjusting washer.
When the backlash is large:
Make drive gear back side adjusting washer thicker, and drive gear tooth side adjusting washer thinner by the same amount.
When the backlash is small:
Make drive gear back side adjusting washer thinner, and drive gear tooth side adjusting washer thicker by the same amount.

CAUTION: Do not change the total amount of washers as it will change the bearing preload.

Companion Flange Runout





1. Fit a dial indicator onto the companion flange face (inner side of the propeller shaft mounting bolt holes).
2. Rotate the companion flange to check for runout.
Runout limit: 0.08 mm (0.0031 inch)
3. Fit a test indicator to the inner side of the companion flange (socket diameter).
4. Rotate the companion flange to check for runout.
Runout limit: 0.08 mm (0.0031 inch)
5. If the runout value is outside the repair limit, follow the procedure below to adjust.
a. Check for runout while changing the phase between companion flange and drive pinion gear by 90° step, and search for the point where the runout is the minimum.
b. If the runout value is still outside of the limit after the phase has been changed, possible cause will be an assembly malfunction of drive pinion and pinion bearing and malfunction of pinion bearing. Check for these items and repair if necessary.
c. If the runout value is still outside of the limit after the check and repair, replace companion flange.

DISASSEMBLY
Differential Assembly
1. Drain gear oil, if necessary.
2. Remove side flange.
3. Remove rear cover mounting bolts.





4. Remove rear cover to insert the seal cutter between gear carrier and rear cover.
Tool number: KV10111100 (J-37228)

CAUTION:
^ Be careful not to damage the mating surface.
^ Do not insert flat-bladed screwdriver, this way damage the mating surface.





5. Using two 45 mm (1.77 inch) spacers, mount carrier on the attachment.
Tool number: KV38100800 (J-25604-01)





6. For proper reinstallation, paint matching marks on one side of the bearing cap.

CAUTION:
^ For matching mark, use paint. Do not damage bearing caps and gear carrier.
^ Bearing caps are line-board during manufacture. The matching marks are used to reinstall them in their original positions.





7. Remove bearing caps.





8. Lift differential case assembly out with a suitable tool.





^ Keep side bearing outer races together with inner race. Do not mix them up. Also, keep side bearing adjusting washers together with bearings.





9. Remove side bearing inner race. To prevent damage to bearing, engage puller jaws in groove.
Tool number A: ST33051001 (J-22888-20)
B: ST33061000 (J-8107-2)

CAUTION:
^ To prevent damage to the side bearing and drive gear, place copper plates between these parts and vise.
^ It is not necessary to remove side bearing inner race except it is replaced.





10. For proper reinstallation, paint matching mark on one differential case assembly.

CAUTION: For matching mark, use paint. Do not damage differential case and drive gear.

11. Remove drive gear mounting bolts.
12. Tap drive gear off differential case assembly with a soft hammer.

CAUTION: Tap evenly all around to keep drive gear from bending.





13. Put matching marks with paint.





14. Loosen screws on differential cases A and B.





15. Separate differential case A and B. then remove viscous coupling, pinion mate gear, pinion mate thrust washer, side gear and side gear thrust washer from differential cases.

Drive Pinion Assembly
1. Remove differential assembly.





2. Remove drive pinion lock nut with the flange wrench.
Tool number: KV40104000 (-)





3. Put matching mark on the end of drive pinion. The matching mark should be in line with the matching mark A on companion flange.

CAUTION: For matching mark, use paint. Do not damage companion flange and drive pinion.

NOTE: The matching mark A on the final drive companion flange indicates the maximum vertical runout position. When replacing companion flange, matching mark is not necessary.





4. Remove companion flange using the suitable puller.





5. Press drive pinion assembly out of gear carrier.

CAUTION: Do not drop drive pinion assembly.

6. Remove front oil seal.
7. Remove side oil seal.
8. Remove pinion front bearing inner race.
9. Remove collapsible spacer.





10. Remove pinion rear bearing inner race and drive pinion height adjusting washer with the replacer.
Tool number: ST30031000 (J-22912-01)





11. Tap pinion front/rear bearing outer races uniformly a brass rod or equivalent to removed.

CAUTION: Be careful not to damage gear carrier.

INSPECTION AFTER DISASSEMBLY





Clean up the disassembled parts. Then, inspect if the parts are worn or damaged. If so, follow the measures below.

ADJUSTMENT AND SELECTION OF ADJUSTING WASHERS
Differential Side Gear Clearance
^ Assemble the differential parts if they are disassembled.

1. Place differential assembly so that right side Gear is on the under side.





2. Measure the clearance between right side gear back and differential case using feeler gauge, while rotating right side gear with a suitable tool attached to splines.
Side gear back clearance specification: 0.15 mm (0.0059 inch) or less. (Each gear should rotate smoothly without excessive resistance during differential motion.)

CAUTION:
^ Do not place feeler gauge at groove side of differential case.
^ To prevent side gear from tilting, insert feeler gauges with the same thickness from both sides.

3. If the back clearance is outside the specification, use a thicker/thinner side gear thrust washer to adjust.
When the back clearance is large: Use a thicker thrust washer.
When the back clearance is small: Use a thinner thrust washer.

CAUTION:
^ Adjust the clearance with the left side gear thrust washer only.
^ Only one side gear thrust washer can be selected.