Assembly

DRIVE PINION

Assembly

1.Select drive pinion adjusting shim. Adjustment.
2.Install selected drive pinion adjusting shim to transfer case.





3.Install outer race of pinion bearing (rear) to the transfer case with the drift (A) [SST: ST-37830000 (-)].

CAUTION:
- Never reuse pinion bearing.
- Apply gear oil to the pinion bearing.





4.Install inner race of pinion bearing (front) to drive pinion with the drift (A) [SST: ST-35272000 (J-26092)].

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

CAUTION:
- Never reuse pinion bearing.
- Apply gear oil to the pinion bearing.





6.Using the drifts (A) (Commercial service tool), install drive pinion oil seal (1) to transfer case within the dimension (L) shown as follows.

L: 0 - 0.6 mm (0 - 0.024 in)

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

CAUTION:
Never reuse the collapsible spacer.
8.Assemble drive pinion assembly into the transfer case, and then install companion flange to drive pinion.
NOTE:





Align matching marks (A) on the thread edge of drive pinion and companion flange, and install companion flange if drive pinion is reused.





9.Tap the companion flange (1) with a plastic hammer as far as the pinion lock nut can be tightened.

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

CAUTION:
Never reuse pinion lock nut.





11.Tighten pinion lock nut within the specified torque range with the preload gauge (A) [SST: ST-3127S000 (J-25765-A)] so that the drive pinion bearing preload is within standard.
Drive pinion bearing preload: Preload Torque.

CAUTION:
- Start the tightening of pinion lock nut from lower limit of the specified torque. Check the preload every 5� to 10�
while tightening the pinion lock nut.
- Replace the collapsible spacer and tighten it again to adjust if preload exceeds the specified value. Never loosen pinion 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.
12.Install ring gear shaft assembly. Assembly.
13.Install transfer cover to check and adjust each part. Assembly.

CAUTION:
Never apply liquid gasket.
14.Check backlash, tooth contact, total preload and companion flange runout. Adjustment.

CAUTION:
Measure the total preload without the transfer case oil seal.
15.Reinstall transfer cover for applying liquid gasket. Assembly.
16.Install the transfer case oil seal (left and right). Assembly.